manual.pdf · 4 westfalia separator ag 1315-9001-060 / 0804 for your safety observe accident...

Mechanical Separation Division

Westfalia Separator AG

Instruction manual

No.: 1315-9001-060

Edition: 0804

Description: Soft Cheese Separator

Model: KDB 45-02-076

2 Westfalia Separator AG

1315-9001-060 / 0804

Westfalia Separator AG 3

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Subject to modification!

Fig. 1

Westfalia Separator

D-59302 Oelde (F. R. Germany)

Model S/N

Built in ø in mm

Max. admissible rated bowl speed in min-1

Max. admissible density in kg/dm3 of product

Heavy liquid kg/dm

3

Solids kg/dm

3

min/max throughput m3/h

min/max temp. of product in °C

min/max housing in bar


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For your safety

Observe accident prevention regulations.

The local safety and accident prevention regulations apply uncondi-tionally to the operation of the separator.

Refer to the instruction manual.

Follow only the instructions given in this manual.

Operate the separator only in accordance with agreed process and operating parameters.

Maintain the separator

as specified in this manual.

Carry out safety checks on the separator,

as described in the chapter "Safety precautions" in this manual.

Liability for the function of the machine passes to the owner.

Liability for the function of the machine passes unconditionally to the owner or operator irrespective of existing warranty periods in so far as the machine is improperly maintained or serviced by persons other than Westfalia Separator personnel or if the machine is not ap-plied in accordance with the intended use. Westfalia Separator AG shall not be liable for damage which occurs as a result of non-compliance with the above. Warranty and liability conditions in the Conditions of Sale and Delivery of Westfalia Sepa-rator AG are not extended by the above.


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Note on the symbols used in the instruction manual

As a result of the continuous adaptation of our instruction manuals to new stan-dards, “mixed” documents may be produced which contain both old and new safety symbols. Below is an explanation of the meaning of the symbols used in the manuals.

Special attention must be paid to all passages in a manual marked with safety symbols. The operation described after such a symbol must be carried out with utmost care.

New symbols:

Caution

This symbol indicates potential danger to persons. (danger to life, risk of injury)

Attention!

This symbol indicates potential risk to risks for machine, material and environment.

Instruction manual

This symbol draws attention to the fact that at this point additional manu-als must be read and observed.

NOTE

This symbol does not indicate safety precautions but rather information for a better understanding of the machine.

Old symbols:

Strictly adhere to instructions marked with this symbol.

This avoids damage or destruction of the separator and other equip-ment.

Take special care when carrying out operations marked with this symbol

otherwise danger to life.


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1 Safety precautions 11

1.1 Fundamental safety precautions ........................................................... 13 1.2 Symbols and abbreviations used ........................................................... 13 1.2.1 Concrete safety precautions and symbols used .................................... 13 1.2.2 Further symbols for information ............................................................. 14 1.2.3 Correct usage ........................................................................................ 15 1.2.4 Incorrect usage ...................................................................................... 15 1.2.5 Unauthorized modification work ............................................................ 16 1.2.6 Use of non-genuine spare parts ............................................................ 16 1.2.7 Obligations of the user ........................................................................... 17 1.2.8 Qualification of the personnel ................................................................ 19 1.3 Special safety precautions ..................................................................... 20 1.3.1 Safety markings on the separator .......................................................... 20 1.3.2 Position of safety devices on the separator ........................................... 22 1.3.3 The main switch on the control cabinet ................................................. 22 1.3.4 EMERGENCY-OFF switches ................................................................ 22 1.3.5 Checking the EMERGENCY-OFF and safety devices .......................... 22 1.3.6 Special risks of a separator ................................................................... 22 1.3.7 Special product hazards ........................................................................ 25 1.3.8 Special hazards caused by cleaning liquid ............................................ 25 1.3.9 Notes on the use of protective equipment ............................................. 26 1.3.10 Safety precautions for transport ............................................................ 27 1.3.11 Safety precautions for start-up............................................................... 27 1.3.12 Safety precautions for the electrical installation .................................... 28 1.3.13 Safety precautions for operation ............................................................ 29 1.3.14 Safety precautions for maintenance and repair ..................................... 29 1.4 Additional notes ..................................................................................... 34 1.4.1 Operating principles ............................................................................... 34 1.4.2 Bowl speed and product ........................................................................ 34 1.4.3 Operations on the separator .................................................................. 35 1.4.4 Assembly ............................................................................................... 35 1.4.5 Before start-up ....................................................................................... 37 1.4.6 Starting ................................................................................................... 38 1.4.7 Maintenance .......................................................................................... 39 1.4.8 Corrosion ............................................................................................... 39 1.4.9 Erosion ................................................................................................... 41 1.5 Sight glasses ......................................................................................... 42 1.6 Steam sterilization ................................................................................. 42 1.7 Operation with hazardous materials ...................................................... 43 1.8 Solids vessel blockage .......................................................................... 43

2 Installation 45

2.1 Transport................................................................................................ 48 2.2 Installation .............................................................................................. 48

3 Lubrication 51

3.1 Bearings and gear ................................................................................. 52 3.1.1 Oil quality ............................................................................................... 52 3.1.2 Oil check ................................................................................................ 52 3.1.3 Oil quantity ............................................................................................. 52


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3.2 Motor bearings ....................................................................................... 52 3.2.1 Oil change .............................................................................................. 53 3.3 Bowl parts .............................................................................................. 53

4 Motor connection 55

4.1 Three-phase AC motor .......................................................................... 56 4.2 Direction of rotation of the bowl ............................................................. 59 4.3 Bowl speed ............................................................................................ 59 4.4 Starting time of the bowl ........................................................................ 61 4.5 Speed measuring device ....................................................................... 61 4.6 Electronic vibration monitoring............................................................... 61

5 Bowl 63

5.1 Important instructions ............................................................................ 64 5.1.1 Special risks of a separator ................................................................... 65 5.1.2 Safety precautions for maintenance and repair ..................................... 67 5.2 Dismantling the feed and discharge connections .................................. 74 5.3 Dismantling the bowl .............................................................................. 76 5.4 Replacing the nozzles with the hood closed .......................................... 80 5.5 Assembling the bowl .............................................................................. 81 5.6 Assembling the feed and discharge connections .................................. 86 5.7 Fitting the nozzles .................................................................................. 88 5.8 Disk stack compressing device.............................................................. 89 5.9 Aligning the concentrate collector .......................................................... 91

6 Technical information 93

6.1 Separator bowl ....................................................................................... 94 6.2 Quark production using the standard process ....................................... 95 6.3 Standard quark processing line ............................................................. 96 6.3.1 Measuring probe .................................................................................... 97 6.4 Quark production using the thermo process .......................................... 98 6.5 Thermo quark processing line ............................................................... 99 6.5.1 Calculation of the quark yield standard process .................................. 101 6.5.2 Calculation of the required amount of skim milk (kg) .......................... 101 6.6 Determining the nozzles ...................................................................... 103 6.7 Installation features .............................................................................. 104

7 Operation 107

7.1 General ................................................................................................ 108 7.2 Before each start-up ............................................................................ 108 7.3 Start-up ................................................................................................ 108 7.4 Operation ............................................................................................. 109 7.5 Shut-down ............................................................................................ 109 7.6 Shut-down “Emergency-Off”. ............................................................... 110

8 Cleaning 111


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8.1 CIP (cleaning-in-place) ........................................................................ 112 8.2 Bowl ..................................................................................................... 115 8.3 Concentrate catcher ............................................................................ 115 8.4 Upper section of the frame .................................................................. 115 8.5 Gear chamber ...................................................................................... 115 8.6 Before a long-term shut-down ............................................................. 116

9 Drive 117

9.1.1 Special risks of a separator ................................................................. 118 9.1.2 Safety precautions for maintenance and repair ................................... 120 9.2 Dismantling the vertical gear parts ...................................................... 125 9.2.1 Removal of ball bearings and worm .................................................... 128 9.2.2 Replacing the slide ring packing .......................................................... 129 9.3 Fitting the vertical gear parts ............................................................... 132 9.3.1 Assembling the neck bearing bridge ................................................... 133 9.4 Bowl height .......................................................................................... 134 9.4.1 Check ................................................................................................... 134 9.4.2 Re-adjustment ..................................................................................... 134 9.5 Removal of the horizontal gear parts ................................................... 136 9.5.1 Removing the motor ............................................................................ 136 9.5.2 Removing the fluid clutch ..................................................................... 137 9.5.3 Worm wheel shaft ................................................................................ 138 9.5.4 Removing the grooved ball bearing (motor side) ................................ 140 9.5.5 Removing the angular contact ball bearing (brake side) ..................... 140 9.6 Assembling the horizontal gear parts .................................................. 143 9.7 Pneumatic brake .................................................................................. 146

10 Fluid clutch 149

10.1 General ................................................................................................ 150 10.2 Checking the oil level: .......................................................................... 150 10.3 Filling in oil ........................................................................................... 151 10.4 Type of oil ............................................................................................ 152 10.5 Dismantling .......................................................................................... 153 10.6 Re-assembling ..................................................................................... 155

11 Trouble shooting 157

11.1 Mechanical function ............................................................................ 158 11.2 Possible causes for inefficient separation ........................................... 161

12 Lubrication and maintenance 163

12.1 Lubrication chart .................................................................................. 164 12.2 Maintenance schedule ......................................................................... 165 12.2.1 Guide to ordering spare parts .............................................................. 166 12.2.2 Use of non-genuine spare parts .......................................................... 167

13 Datasheet 169


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13.1 Datasheet............................................................................................. 171


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Note Notes

Notizen Anotaciones

Notizen Notes Note


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1 Safety precautions

1.1 Fundamental safety precautions ........................................................... 13 1.2 Symbols and abbreviations used ........................................................... 13 1.2.1 Concrete safety precautions and symbols used .................................... 13 1.2.2 Further symbols for information ............................................................. 14 1.2.3 Correct usage ........................................................................................ 15 1.2.4 Incorrect usage ...................................................................................... 15 1.2.5 Unauthorized modification work ............................................................ 16 1.2.6 Use of non-genuine spare parts ............................................................ 16 1.2.7 Obligations of the user ........................................................................... 17 1.2.8 Qualification of the personnel ................................................................ 19 1.3 Special safety precautions ..................................................................... 20 1.3.1 Safety markings on the separator .......................................................... 20 1.3.2 Position of safety devices on the separator ........................................... 22 1.3.3 The main switch on the control cabinet ................................................. 22 1.3.4 EMERGENCY-OFF switches ................................................................ 22 1.3.5 Checking the EMERGENCY-OFF and safety devices .......................... 22 1.3.6 Special risks of a separator ................................................................... 22 1.3.7 Special product hazards ........................................................................ 25 1.3.8 Special hazards caused by cleaning liquid ............................................ 25 1.3.9 Notes on the use of protective equipment ............................................. 26 1.3.10 Safety precautions for transport ............................................................ 27 1.3.11 Safety precautions for start-up............................................................... 27 1.3.12 Safety precautions for the electrical installation .................................... 28 1.3.13 Safety precautions for operation ............................................................ 29 1.3.14 Safety precautions for maintenance and repair ..................................... 29 1.4 Additional notes ..................................................................................... 34 1.4.1 Operating principles ............................................................................... 34 1.4.2 Bowl speed and product ........................................................................ 34 1.4.3 Operations on the separator .................................................................. 35 1.4.4 Assembly ............................................................................................... 35 1.4.5 Before start-up ....................................................................................... 37 1.4.6 Starting ................................................................................................... 38 1.4.7 Maintenance .......................................................................................... 39 1.4.8 Corrosion ............................................................................................... 39 1.4.9 Erosion ................................................................................................... 41


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1.5 Sight glasses ......................................................................................... 42 1.6 Steam sterilization ................................................................................. 42 1.7 Operation with hazardous materials ...................................................... 43 1.8 Solids vessel blockage .......................................................................... 43


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1.1 Fundamental safety precautions

These general safety precautions form part of the overall documentation pack-age furnished with the separator. They contain information which is important for safe handling of separators.

Every person assigned the responsibility of installing, operating, maintaining and repairing the separator must have read and understood the documentation, in particular the chapter safety precautions.

Maintenance and repair work may only be carried out by the user to the extent described in this instruction manual. The user must ensure that all work is car-ried out by suitably qualified personnel (see also “Qualification of the person-nel”).

Maintenance and repair work not described in this manual may only be carried out by the manufacturer or by "repair shops" authorized by the manufacturer.

The instruction manual and further documentation required for the operation of the separator / plant must be complete and kept in the vicinity of the separator for ready access by the operating personnel. It must be available to the opera-tors at all times. Damaged and/or illegible parts must be replaced.

1.2 Symbols and abbreviations used

In the following instruction manual, concrete safety precautions are given to draw attention to the non-avoidable residual risks when operating the machine.

The symbols and warning signs used in the instruction manual correspond to the symbols used in standard sets of regulations. They are described in detail in the chapter Safety precautions and are intended to draw attention to potential danger sources to minimise the risk of accidents for persons and / or damage to property.

1.2.1 Concrete safety precautions and symbols used

These residual risks involve hazards for

persons

product and machine

environment.

The symbols used in the instruction manual are above all designed to draw at-tention to the safety precautions.

Caution

This symbol indicates potential danger to persons. (danger to life, risk of injury)


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Attention!

This symbol indicates potential risks to machine, material and environ-ment.

The most important aim of the safety precautions is to prevent damage to per-sons.

When the warning triangle in front of a safety precaution bears the caption “Caution", risks for machine, material and environment are not excluded.

When the warning triangle in front of the safety precaution bears the caption “Attention”, risks to persons are not to be expected.

The respective symbol used cannot replace the text of the safety precaution. Therefore, always read the complete text!

1.2.2 Further symbols for information

The following symbols are not safety precautions but represent information and notes to enable better understanding of the machine or plant and processes.

Instruction manual

This symbol draws attention to the fact that at this point additional manu-als must be read and observed.

If the stop sign with the caption “Instruction manual” is in front of a note, an-other furnished manual must be referred to and the instructions and notes ob-served.

NOTE

This symbol does not indicate safety precautions but rather information for a better understanding of the machine.

When the info symbol with the caption “Note” is adjacent to a text, the reader is given useful tips, explanations and notes on the machine, plant or its proc-esses.


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1.2.3 Correct usage

The separator is used for the separation of media with different densities.

Separators are used for the separation of liquid mixtures or for the separation of solids out of liquids or liquid mixtures.

The separator is designed

in accordance with the chemical and physical properties of the product speci-fied for correct usage of the separator and

in accordance with the method of application contractually agreed with West-falia Separator AG.

The separator may be operated only in the agreed areas and with the parame-ters specified in the documentation or a datasheet which is part of the documen-tation.

Any operating mode deviating herefrom is not proper and correct and can cause damage to persons and property.

In particular, only products may be used which conform to the specifications on the separator nameplate.

The instructions, notes and specifications in the instruction manual must be fol-lowed.

1.2.4 Incorrect usage

All operating modes not detailed under correct usage are considered to be in-correct usage.

Products not specified in the documentation or on a datasheet furnished with the documentation may not be used.

Constructional alterations may not be made to the separator, fittings and other accessories.

Use only those operating materials specified in the technical data or technical specifications (lubricating greases, cleaning agents, operating liquids etc.)!

Process parameters such as

– admissible pressures

– admissible temperatures

– admissible flow rates

– torques

– settings


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which are specified in the user information or a datasheet furnished with the user information must not be exceeded.

Prior to any intended deviation from the agreed operating mode, it is imperative to obtain the consent of Westfalia Separator.

NOTE

Westfalia Separator shall not accept liability for damage arising from in-correct usage.

1.2.5 Unauthorized modification work

No conversion work or modifications may be carried on the separator or plant by the user.

Conversions or modifications on the separator or plant can

– endanger life and limb of the user or third parties.

– impair the operating safety of the separator.

– lessen the efficiency of the separator / plant.

– result in damage to the separator itself or other components within the plant.

Westfalia Separator shall not accept liability for damage arising from un-authorized conversion or modification to the separator or plant.

1.2.6 Use of non-genuine spare parts

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 plant availability.

If a safety risk arises, this may have legal consequences for the responsible persons. In this case, Westfalia Separator shall assume no liability or warranty.

Damaged separator parts must be replaced by new genuine spare parts from Westfalia Separator.


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1.2.7 Obligations of the user

The separator corresponds to the state-of-the-art of the year of its construction. It makes possible a high level of safety when operated for its correct intended use.

In practical operation, however, the high safety standard can only be maintained through compliance with all required measures. The user must therefore prac-tice the required care and diligence in planning these measures and monitoring their execution.

The use must in particular comply with national legislation and directives.

The user must, for example, ensure that

the separator is applied only for the intended use (see section Correct us-age).

the separator is operated only in a perfect functional condition and the func-tion of the safety devices is regularly checked.

necessary personal protective gear is available and worn by operating, main-tenance and repair personnel.

the instruction manual is always available at the separator site in a complete and legible condition.

only qualified and authorized personnel operate, maintain and repair the separator.

this personnel receives regular instruction on all relevant issues relating to in-dustrial safety and is familiar with the instruction manual and, in particular, the safety precautions contained in it.

all safety and warning signs are not removed and remain legible.

a plant instruction on conduct at the workplace is issued by the user and made known to the personnel.

in Germany the local accident prevention regulations of the employer's liability insurance association are complied with.

safe access to the machine is assured for maintenance and repair work, for example by means of catwalks and working platforms.

the corresponding statutory safety regulations for the protection of life and health are adhered to.


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NOTE

Assembly and commissioning personnel of Westfalia Separator have been directed to abort operations when statutory safety regulations at the site of deployment are not fulfilled and there is a risk to life and health.

The user must ensure that the required hoists, devices and aids are available to ensure safe handling of the separator during assembly work.


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1.2.8 Qualification of the personnel

The separator may only be operated, maintained and repaired by trained per-sonnel.

The user of the separator is responsible for training.

The personnel must likewise receive instruction in the required accident preven-tion measures and know and understand the plant instructions.

The user must deploy personnel who are capable of

– fulfilling the requirements to be met by the personnel for operating the separator.

– reading the markings on the separator and the instruction manual.

The personnel must be trained to carry out the following operations on the sepa-rator:

Operation

Maintenance

Repair

The user is acting with gross negligence when he deploys untrained, unsuitable personnel for work on the separator and knowingly exposes the personnel to a life-threatening risk.

Operation of the separator or plant by untrained or unauthorized personnel can result in

– danger to life and limb of the user or third parties.

– impairment of or damage to the separator or plant or other assets of the user.

– reduction of the efficiency of the separator or plant.

Westfalia Separator shall accept no liability for damage caused by un-qualified or unauthorized personnel.

Westfalia Separator offers a comprehensive range of training measures. Con-tact Westfalia Separator or one of its authorized representatives for further in-formation.


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1.3 Special safety precautions

The following safety precautions apply for separators and plant components de-livered by Westfalia Separator.

1.3.1 Safety markings on the separator

The following warnings are attached to the separator as safety markings. The safety markings must always be in perfect condition. They are part of the user information.

Clean dirty safety markings.

Replace damaged safety markings.

Fig. 2

1) Only in case of frequency converter operation

2) Only in case of hot operation

The position of safety markings on the separator is illustrated in chapter “De-sign and function”.


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Meaning of the safety markings

This safety marking means: Do not carry out maintenance or repair work on the separator before the bowl has come to a standstill. Danger of injury due to rotating machine parts!

This safety marking means: Attention in the case of unusual noises or vibrations on the separator! Follow the instructions in the instruction manual! Danger to life and limb through rotating machine parts!

This safety marking means: Before working on the separator and electrical plant components: Disconnect power to the separator and plant components and secure against unintentional switching on! Danger of injury through electrical current and unintentional start-up of the separator!

This safety marking means: Attention, do not manipulate the frequency converter (electronic speed adjustment)! Setting the parameters on the frequency converter may only be carried out by qualified specialists. The admissible maximum bowl speed as stated on the nameplate may not be exceeded! When starting the machine, for example after replacing drive parts, the bowl speed must be checked. The separator may only be operated with an additional independent de-vice for speed limiting. Risk of damage to the separator!

This safety marking means: Attention, the surfaces of the separator and plant components can be hot or cold. Danger of injury through hot or cold surfaces!


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1.3.2 Position of safety devices on the separator

Special safety devices such as sensors are customer-specific and must not be changed.

1.3.3 The main switch on the control cabinet

Precise information on the position of the main switch on the control cabinet is given in the electrical documentation. The control cabinet is installed in accordance with the installations of the user. The position of the main switch must therefore be taken from the plant instructi-on of the user.

1.3.4 EMERGENCY-OFF switches

EMERGENCY-OFF switches are located in the control cabinet. Precise information on the position of the EMERGENCY-OFF switches is given in the electrical documentation. The control cabinet is installed in accordance with the installations of the user. The position of the EMERGENCY-OFF switches must therefore be taken from the plant instructions of the user.

1.3.5 Checking the EMERGENCY-OFF and safety devices

The safety devices must be correctly installed and checked for functionality be-fore start-up.

1.3.6 Special risks of a separatorThe separator is equipped with a high-speed ro-

tating metal bowl which represents a danger potential not to be underestimated on account of the rotational energy which can pose a danger for the installation and persons working in the installation when not properly handled.

CAUTION!

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! 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 indicating option for standstill will provide false information because, for example, the electronics have failed or the belt or gear 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

The inspection port on the hood enables a direct view onto the bowl. In addi-tion, checking is possible by removing the gear cover or opening the frame port on the bowl side.


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Revolution visual check on ma-chines with belt drive. You can observe whether the machine is at a standstill at the points marked with the arrows. We reserve the right to carry out de-sign modifications.

Fig. 3

NOTE

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.

Revolution visual check on ma-chines with gear. You can observe whether the machine is at a standstill at the points marked with the arrows. We reserve the right to carry out de-sign modifications.

Fig. 4

NOTE


During cleaning programs (steam sterilization and CIP), very high temperatures are reached on the surfaces of the separator and piping.


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CAUTION!

During cleaning programs, the surfaces of the separator and pipes are very hot. Danger of burns!

With some products, the separator has to be cooled. As a result, temperatures of up to minus 30 °C are reached on the surfaces of the separator and pipes.

CAUTION!

When the cooling is switched on, the surfaces of the separator and pipes can get very cold. Danger of frostbite!

CAUTION!

When the noise level of the separator is too high, noise-dampening ear protectors must be worn. Danger of hearing damage!

CAUTION!

During all maintenance and repair work on the separator, the fittings and pipes may spit out hot, caustic liquids. Danger of causticization of skin and eyes!


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1.3.7 Special product hazards

In the case of products which have to be allocated to a specific hazard class, adhere to the corresponding local safety precautions when handling these products.

Follow the local plant instructions and wear the required protective gear.

In the event of accidents, keep to the local rules of conduct when handling products of the respective hazard classes and take appropriate first-aid measures when injury is involved.

If necessary, notify the in-house task forces immediately when an accident occurs (fire-brigade, medics, plant security, disposal teams etc.) so that fur-ther action can be taken.

1.3.8 Special hazards caused by cleaning liquid

Only those chemicals may be used for the chemical cleaning process (CIP) which are specified in the user information or a datasheet issued with the user information.

CAUTION!

High temperatures are reached during cleaning! Surfaces of separator hood and pipes are hot! Danger of burns!

Follow the local plant instructions and wear the required protective gear.

Keep to the local procedures when handling acids and lyes to avoid accidents and take appropriate first-aid measures if injuries do occur.

If necessary, notify task forces immediately when an accident occurs (fire-brigade, medics, plant security, disposal teams etc.) so that further action can be taken.


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1.3.9 Notes on the use of protective equipment

To avoid danger to life and limb, the specified protective gear must be worn by operating, maintenance and repair personnel in line with the

– local accident regulations

– instructions of the user and

– the safety precautions described in this instruction manual.

The following protective gear must be worn when in the vicinity of or working on the separator

Wear ear protection!

Wear ear protection during operation of the separator! (noise emissions 84 dB(A) or higher)

Wear protective gloves!

Wear protective gloves when working on hot or cold surfaces of separator and piping. (possible temperature ranges <-10 to >80°C or <14 to >176 °F)

Wear protective goggles!

Wear protective goggles when working on pipes and fittings. (Possible residues of caustic liquids in valves and pipes and piping sys-tem not relieved from pressure)


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1.3.10 Safety precautions for transport

For loading and unloading operations, use only hoists and load carrying equipment with adequate lifting power (the weight of the separator is specified in the documentation or a datasheet furnished with the documentation).

CAUTION!

When transporting and assembling machine parts: Danger of crushing!

Transport the separator only with removed bowl.

Lift the separators correctly only in accordance with the specifications in the user information (lifting points etc.) using a hoist!

Do not use damaged or incomplete load carrying equipment.

Appoint a competent instructor for the lifting process!

When using load carrying equipment and hoists, observe the statutory regula-tions and safety regulations.

Use only a suitable transport vehicle with adequate lifting power!

Reliably secure the load. Use suitable lifting points.

After loading, provide the separator with devices which prevent a shift in posi-tion (sliding, moving).

1.3.11 Safety precautions for start-up

Check that all screwed connections are tight.

Check that the lock rings on the bowl are tight.

Pay particular attention to the bowl lock ring: After tightening the bowl, the adjusting marks must be in the specified position (e.g. “O” marks on the bowl parts, see figure).

Fig. 5


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CAUTION!

Pay attention to the correct adjustment of the disk compression! An incorrect disk compression can lead to severe imbalance which can in turn result in damage to the separator and danger to life and limb of the user!

Follow the instructions on bowl assembly in the chapter Maintenance and repair.

The direction of rotation of the bowl must correspond to the direction of rotation arrow on the frame or solids catcher.

The direction of rotation of the bowl is normally clockwise when looked at from above.

The separator may only be operated with protection devices conforming to EN 294.

Carry out all testing and checking operations in accordance with the commis-sioning instructions in the instruction manual.

1.3.12 Safety precautions for the electrical installation

The local regulations apply for the electrical appliances and installa-tions.

The frequency and voltage of the power supply must correspond to the machine specifications.

Carry out voltage equalization.

Observe statutory regulations; e.g. in the EU the EG guidelines:


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1.3.13 Safety precautions for operation

Never carry out work on the separator when the bowl is rotating.

Do not loosen any part before the bowl has come to a standstill!

When unusual noises or vibrations occur, press EMERGENCY-OFF immedi-ately and leave the danger zone.

CAUTION!

When unusual noises or vibrations occur: – Never initiate a bowl ejection! – Evacuate the room! – Do not enter the room again until the bowl has come to a standstill! Danger to life and limb through machine parts being thrown around!

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 material.

1.3.14 Safety precautions for maintenance and repair

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. Adapt the maintenance intervals to the operating conditions!

Timely maintenance of the separator is essential for safe operation.

Especially highly stressed parts of the separator such as

– bowl lock ring, – bowl bottom, – bowl top

must be regularly checked (at least once a year) as specified in the maintenance schedule to as-sure safe and efficient operation.

Fig. 6


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When carrying out maintenance and repair work:

Do not climb onto or stand on the machine or parts of the machine!

Danger of injury through slipping or falling down!

Fig. 7

Repairs to the separator may only be carried out by service technicians from Westfalia Separator or personnel trained and certified by Westfalia Separator.

During maintenance and repair work, make sure that the main switches are switched off and se-cured against restarting.

Make sure that other persons do not have the possibility to start the ma-chine before the maintenance or re-pair work is finished.

Fig. 8

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.


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Do not heat bowl parts with a na-ked flame to facilitate dismantling work.

Structural changes in the material of the bowl parts which affect the operating safety of the machine may result!

Do not weld bowl parts.

Fig. 9

Do not weld hood and solids catcher parts of steam-sterilizable separators.

Place the dismantled separator parts on suitable surfaces (rubber, wood etc.).

Take appropriate steps to prevent machine parts from overturning and rolling away.

Fig. 10

When carrying out assembly work on several separators, be careful not to interchange parts of different bowls! Each bowl must be balanced with its respective components.

The parts are marked with the serial number of the machine or with the last three digits of the serial number.

Fig. 11


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Some bowl parts must be arranged in fixed positions relative to one an-other.

Locking devices and alignment marks must be in perfect condition.

The separator may not be oper-ated when locking devices and marks on the bowl parts are dam-aged.

Fig. 12

After fitting certain bowl parts (e.g. bowl bottom, bowl top) the bowl must be re-balanced.

Bowl balancing may be carried out only by specialists from Westfalia Separator or special-ist workshops authorized by Westfalia Separator! If in doubt, consult the service department of Westfalia Separa-tor.

Fig. 13

Do not manipulate speed-altering devices such as frequency converters so that the maximum admissible bowl speed (see nameplate or “technical data” in the instruction manual) is not exceeded.

Ensure that monitoring devices (e.g. overspeed monitors etc.) are not ma-nipulated or damaged and check their function in accordance with the instruc-tions in chapter “Maintenance and repair – maintenance schedule”.

When carrying out maintenance and repair work, carry out a visual check of the separator components. Have the components checked for damage through corrosion and erosion by authorized specialists and proceed in accordance with the instructions in chapter “Maintenance and repair – in-spections”.

Caution

The separator must be shut down immediately when damage due to corrosion or erosion is detected! There is a risk of damage to the separator and a danger to life and limb of the user through machines parts flying around.

In case of doubt, contact Westfalia Separator!


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Follow the instructions when han-dling waste oils and comply with the disposal regulations when replacing lubricants in the chapter “Mainte-nance and repair” of the instruction manual.

Fig. 14

After maintenance and repair work on the separator, refit all protective de-vices.


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1.4 Additional notes

1.4.1 Operating principles

Separators are used for the separation of liquid mixtures or for the separation of solids out of liquids or liquid mixtures.

High centrifugal forces are produced in the rotating bowl of the separator.

Fig. 15

Under the influence of the centrifugal forces, separation of the liquid mixture and/or ejection of the solids particles takes place within a very short space of time.

The specifically heavier components are displaced to the bowl periphery, whereas the specifically lighter components are displaced towards the centre of the bowl.

The high centrifugal force is produced by very high bowl speeds. On the one hand, high bowl speeds signify high efficiency, while on the other hand, they signify high material stressing of the separator.

1.4.2 Bowl speed and product

The bowl speed is an important parameter when rating the separator. It de-pends on the chemical and physical properties of the product such as

Temperature

Density of the fluid and solid components

Aggressiveness of the product as regards corrosion and erosion (influences the selection of the bowl material).

The bowl speed is determined on the basis of these parameters allowing for an adequate safety margin.

Before using a product with properties different from those stated when placing the order, it is imperative to obtain the manufacturer's approval.


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1.4.3 Operations on the separator

The separator works safely and reliably, provided that it is operated and main-tained in accordance with our operating instructions.

Special attention must be given to:

Assembly

Starting

Maintenance and servicing

1.4.4 Assembly

If the plant has several centrifuges, be careful not to interchange parts of different bowls since each bowl has been balanced individually. The parts are marked with the serial number of the machine or with the last three digits of the serial number.

Fig. 16

Replace damaged parts by new or reconditioned parts.

Fig. 17


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After installing certain critical spare bowl parts, the bowl must be re-balanced. (for further details, see bowl assembly)

Fig. 18


Locking devices and alignment marks must be in perfect condition. Otherwise, the bowl may not be op-erated.

Fig. 19

When assembling the bowl, be sure to strictly adhere to the instructions given in chapter "bowl", in order to avoid undue unbalance.

Before starting the bowl, be sure to fit all parts.

Tighten the bowl lock ring securely: the "O" marks on the bowl bottom or bowl top and on the lock ring must be in line with each other. (for further details, see bowl assembly)

Fig. 20


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Check if the machine is completely assembled and properly installed.

Fig. 21

Carefully fasten hood 1, feed and discharge housing 2 and centripetal pump 3.

Fig. 22

1.4.5 Before start-up

Check that the supervisory equip-ment is operational and the correct limit values are adjusted.

When hoods, concentrate collectors and vessels are pressurized, e.g. by – inert gas, – cooling, – steam sterilization etc. the pressures stated on the name-plate must not be exceeded.

Fig. 23


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Check that the product lines are set to operation.

Regularly check hoses for signs of ageing.

Check sight glasses for mechanical damage.

Replace damaged parts by new or reconditioned parts.

Fig. 24

1.4.6 Starting

Refer to chapter ”operation”.

Note nameplate. The values for – bowl speed – density of the heavy liquid – density of solids (centrifugally dry) are maximum values and must not be exceeded.

Fig. 25


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1.4.7 Maintenance

1.4.8 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 using non-destructive techniques. At the initial stage pitting corrosion is generally caused by chlorine ions.

Depending on the stressing of the part, pitting corrosion can result in crack for-mation.

Possible formation of pitting corrosion.

Fig. 26

Such pittings can only be investigated by a materials expert.

In case of crack-shaped corrosion attack on bowl parts with or without super-posed flat-spread and pit-shaped corrosion, the separator must be shut down immediately.

Contact your nearest Westfalia Separator representative for a thorough exami-nation.


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Pittings

Such pittings should be investigated by a materials expert.

Pittings which are close together or form a linear pattern can signify crack formation beneath the surface.

Fig. 27

Signs of corrosion which you should immediately report to your nearest Westfalia Separator representative:

The bottom of the corrosion mark has a radius smaller than 1 mm (large notch effect).

The depth of corrosion mark ex-ceeds 1 mm at the deepest point.


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1.4.9 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

high throughput capacities

The first signs of erosion should be carefully observed and documented. Ero-sion can deepen rapidly, thereby weakening the high-stressed bowl material.

Contact your nearest Westfalia Separator representative for a thorough exami-nation. Information on the nature of the damage can be provided in the form of photos, plaster casts or lead molds.

The surfaces most susceptible to erosion ar


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Fig. 28

The surfaces most susceptible to erosion are: 1) The bottom of the distributor 2) The centripetal pump (cavitation) 3) All surfaces in the area of the solids discharge ports 4) The nozzles

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 at the deepest point.

Fig. 29

1.5 Sight glasses

NOTE

When the wall thickness of a sight glass or sight glass housing has de-creased by more than 10 %, the centrifugal mixer may not be operated again until the sight glass and / or sight glass housing have been re-placed.

Consequently, all sight glasses in the feed and discharges of separators as well as all other sight glasses in its environment must be checked for wear on a regular basis. More detailed information on this is given in the DIN standards 7097 and 7080.

1.6 Steam sterilization

Separators which are designed for steam sterilization may only be sterilized with hot steam when the machine is at standstill. Maximum steam overpressure: see boilerplate

Attention: Hoods and solids catchers of steam-sterilizable separators are pressure vessels and may not be welded (consult the factory).

To prevent burns:

– Cordon off the separator and steam-carrying plant components to prevent persons coming into contact with them (chains, barriers etc.).

– Attach a yellow warning light that blinks to indicate that sterilization is in progress.


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1.7 Operation with hazardous materials

Extra special care must be taken when working on separators that are process-ing caustic substances such as acids and lyes or other dangerous products.

Machines that are operated with caustic substances are marked with the follow-ing safety sticker.

This safety marking means: Caution! Wear protective equipment whenever working on the separator. Caustic substances can be a risk to life and limb and cause damage to machines and installation plants. Danger of injury through caustic substances!

The stickers must always be in perfect condition.

Clean dirty stickers.

Replace damaged stickers.

In addition to observing the standard safety precautions that apply when work-ing on separators, protective equipment must be worn when working on separa-tors fed with dangerous products to avoid injuries.

Protective equipment consists of, for example:

NOTE

– Face screen – Protective suit – Protective gloves – Protective boots – Apron, etc.

1.8 Solids vessel blockage

The solids vessel can block during:

start-up or shut-down,

running production or

a cleaning cycle.

Remedy:

Switch off the installation in accordance with the installations.

Put on the prescribed personal protective clothing and equipment.

CAUTION!

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 loosen any part before the bowl has come to a standstill! When operating the separator with hazardous products, there is a danger of fatal injury!


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Loosen the screw coupling of the solids pump and empty the solids vessel as far as possible.

Open the inspection cover and remove the blockage from above. For this purpose, use a suitable tool since the vessel may contain caustic substances.

Once the work is finished, carefully close and firmly tighten all screw cou-plings.


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2 Installation

2.1 Transport................................................................................................ 48 2.2 Installation .............................................................................................. 48


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Fig. 30


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Subject to technical modifications - refer to project-related dimensioned drawing ! A = Minimum lifting capacity of hoist for removing the bowl 600 : kg B = Min. height of hoist for removing the bowl : 3 410 mm C = Total height approx. 1 796 mm D = Minimum clearance approx. 700 mm E = Clearance needed for removal of motor approx. 700 mm

Note: Subject to technical modifications - detailed dimensions are given in the project-related dimen-sioned drawing supplied with the separator.


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Fig. 31

2.1 Transport

Attach transport ropes to the separator as shown above and hang it into the load hook of the hoist.

Do not suspend the machine from the eye bolt on the motor.

Wind one piece of rope twice around the hook to prevent the ropes from slip-ping.

When lowering the separator, make sure it touches down gently.

2.2 Installation

When installing the separator, make sure there is sufficient space (see dimen-sioned drawing) for fitting and removing the motor and for removing the horizon-tal gear parts which are pulled out towards the brake side.

The foundation must not be connected to the foundations of other vibrating units to prevent damage to the ball bearings.

For installing and removing the bowl, a hoist with a minimum lifting capacity of 600 kg is required.

Do not fit a shut-off valve in the frame drain so that overflowing liquid can flow off freely. Otherwise the liquid will rise in the frame and brake the bowl.

Attention!

Note: Dismantle the motor protective hood before transporting the separator!


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1 Rubber-metal cushion

2 Screw

3 Flange

4 Bolt

5 Foundation frame

6 Anchor bolt

7 Base plate

Fig. 32

Place the first rubber cushion 1a and flange 3 on bolt 4.

Screw bolts into the four cams of foundation frame 5 as far as it will go.

Embed the foundation frame in the floor so that the cams of the frame pro-trude from plates 7 by approx. 55 mm.

Make sure the cams are absolutely level and fasten under observation of lo-cal regulations (e.g. with approved floor anchors).

Place the second rubber cushion 1b on the bolts and then the separator on the bolts.

Bolt flange 3 to the separator frame with screws 2.


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3 Lubrication

3.1 Bearings and gear ................................................................................. 52 3.1.1 Oil quality ............................................................................................... 52 3.1.2 Oil check ................................................................................................ 52 3.1.3 Oil quantity ............................................................................................. 52 3.2 Motor bearings ....................................................................................... 52 3.2.1 Oil change .............................................................................................. 53 3.3 Bowl parts .............................................................................................. 53


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3.1 Bearings and gear

All bearings of the separator are splash-lubricated by:

– -Immersion of the toothed rim of the wormwheel in the central oil bath. (All bearings are splashed with oil due to centrifugal force.)

3.1.1 Oil quality

As lube oil use only gear oils with the WS part number stated in the parts list or on the data sheet.

NOTE

Do NOT use motor vehicle gearbox or engine oils.

3.1.2 Oil check Check oil level daily!

Attention

Check from time to time if oil contains water. To do this, loosen oil drain screw and allow a small amount of oil to drain out.

If the oil shows a milky colouring (emulsification) an immediate oil change is necessary.

3.1.3 Oil quantity

Before the initial start-up of the separa-tor:

remove gear sight glass and fill gear chamber with oil.

Amount: See data sheet Minimum oil level: slightly above middle of sight glass. Maximum oil level: up to upper third of sight glass

Fig. 33

Attention

During operation the oil level must never be allowed to sink below the middle of the sight glass; refill oil when necessary.

3.2 Motor bearings

Instruction manual

For lubrication of the motor bearings, refer to the instructions of the manufacturer (see motor plate).


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3.2.1 Oil change

Make first oil change after about 250 operating hours; then

change oil every 500 operating hours. However be sure not to wait longer than 6 months to change the oil.

Each time when changing the oil, thoroughly clean gear chamber and flush it with thin-bodied oil before filling in new oil.

Remove all metal particles from inner walls and corners of the gear chamber.

Do not use fluffy cleaning rags or cotton waste.

Clean sight glass.

3.3 Bowl parts

Before assembling the bowl, apply a thin film of one of the lubricants specified below to threads and contact surfaces of

- bowl bottom,

- piston,

- bowl top,

- lock rings, etc.

For separators operating in the food processing industry we recommend you to use the following lubricants:

Klüber Grease KSB 8 (may be used in excess).

For separators operating in the chemical industry we suggest using:

Molykote G

Molykote G Rapid

Gleitmo 800

Besides the above mentioned lubricants, other pastes or greases with the same properties may also be used.

N. B.:

Attention

When assembling make sure the gaskets made of the special material EPDM (Ethylene- propylene- diene- caoutchouc) do not come into contact with mineral oils and greases as this would cause the gaskets to swell.

Silicon greases can be used for these gaskets to facilitate assembly.

The greased surfaces must be free from sand and filings. Otherwise the surfaces can become scored.

Also marks caused by knocks to threads, bearing and guide surfaces of the bowl parts can lead to seizing.

Therefore, the threads, contact and guide surfaces must always be checked after cleaning.


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4 Motor connection

4.1 Three-phase AC motor .......................................................................... 56 4.2 Direction of rotation of the bowl ............................................................. 59 4.3 Bowl speed ............................................................................................ 59 4.4 Starting time of the bowl ........................................................................ 61 4.5 Speed measuring device ....................................................................... 61 4.6 Electronic vibration monitoring............................................................... 61


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4.1 Three-phase AC motor

All separators are driven by three-phase motors. Depending on the construction, the following drive variants are available:

Direct drive

– with frequency converter

Gear drive

– with fluid or centrifugal clutch

Belt drive

– with controlled torque motor

– with frequency converter

– with clutch

NOTE

The technical specifications on the motor supplied are given in the data-sheets supplied with the documentation, the motor nameplate and / ort he documentation of the motor manufacturer. 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.

– with frequency converter approx. rated current

– with fluid or centrifugal clutch approx. 1.5 – 2 times rated current

– with controlled torque approx. 2 – 3 times rated current

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.

Attention!

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 motor manufacturer on the motor nameplate.


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Motor with frequency converter (FC)

Pay attention to the following when operating the separator with frequency con-verter:

Attention!

The separator must never be started without frequency converter.

The frequency on the frequency converter must be selected so that the maximum admissible bowl speed is not exceeded. The admissible bowl speed is indicated on the nameplate of the separator.

NOTE

The frequency converter has a frequency limiter to prevent operating at inadmissibly high bowl speeds. In addition, a speed sensor is installed on the separator which sends pulses to the control system for monitoring the bowl speed. The controls switch off the separator when the ceiling speed is exceeded. The separator must only be operated with this auxiliary device. The ceiling speed must be set to 5% above rated speed (see separator nameplate).

Important measures to take during commissioning:

Check the correct setting of the monitoring devices in accordance with the cir-cuit diagram and setting instructions.

Check the speed of the drive spindle:

Test the safety circuit.

Attach the following safety stickers and check that they are properly attached and in good condition:

Fig. 34

– Frequency converter operation! Attention Residual voltage possible


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Fig. 35

CAUTION!

Before carrying out maintenance or repair work on the motor, bear in mind that there may still be residual voltage.

In this connection, refer to the documentation of the frequency converter manu-facturer and have safety measures implemented by suitable personnel.

Frequency converter operation! Do not exceed admissible bowl

speed. See nameplate.


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4.2 Direction of rotation of the bowl

CAUTION!

The bowl must rotate in clockwise direction when looked at from above.

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 authorised specialist.

4.3 Bowl speed

The bowl speed has been defined to assure operating safety as a function of the densities of the centrifugally dry solids and the clarified liquid.

The bowl speed and maximum admissible densities are stated on the nameplate of the separator. When processing products with densities higher than those stated on the nameplate, consult the factory.

CAUTION!

The bowl speed stated on the separator nameplate must not be ex-ceeded.

In the case of separators with belt drive: Check the spindle speed with a hand tachometer:

after replacing the drive belt and/or the belt pulleys.

Fig. 36

In the case of separators with gear: Check the spindle speed with a hand tachometer:

after replacing the gear.

When a revolution indicator disk 1 is fitted, it

indicates that the separator is in operation

shows the direction of rotation.

monitors the operating speed

Fig. 37


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NOTE

The spindle speed must be checked before the first start-up and before fitting the bowl.


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4.4 Starting time of the bowl

NOTE

Specifications on the starting time of the bowl are given in the enclosed data sheets.

Make sure that the bowl reaches its rated speed within the starting time and that this speed is maintained during operation.

Separators with a motor controlled by frequency converter can be re-started any time.

IMPORTANT

The following applies for separators with controlled torque motors:

Re-starting after the motor has reached a constant operating temperature is permitted only after 60 minutes. Non-observance of this instruction can lead to overheating of the clutch or mo-tor.

4.5 Speed measuring device

When the separator is equipped with a speed measuring device, detailed expla-nations are given in the documentation furnished with the separator control.

4.6 Electronic vibration monitoring

Electronic vibration monitoring systems protect the separator against inadmis-sibly high vibration levels.

If certain preset limit values are exceeded, an alarm is given and follow-up measures are initiated.

Vibration monitoring of the bowl spindle

On some separators, a further proximity switch for additional vibration monitor-ing of the bowl spindle is fitted. When bowl imbalance occurs (= vibratory motion of the spindle), this information is transmitted to a downstream evaluating unit and/or indicator and the necessary follow-up measures are initiated.


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5 Bowl

5.1 Important instructions ............................................................................ 64 5.1.1 Special risks of a separator ................................................................... 65 5.1.2 Safety precautions for maintenance and repair ..................................... 67 5.2 Dismantling the feed and discharge connections .................................. 74 5.3 Dismantling the bowl .............................................................................. 76 5.4 Replacing the nozzles with the hood closed .......................................... 80 5.5 Assembling the bowl .............................................................................. 81 5.6 Assembling the feed and discharge connections .................................. 86 5.7 Fitting the nozzles .................................................................................. 88 5.8 Disk stack compressing device.............................................................. 89 5.9 Aligning the concentrate collector .......................................................... 91


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5.1 Important instructions

Forces are produced in the high-speed rotating bowl that can endanger the op-erating safety of the separator if it is not properly assembled or cleaned. The in-structions for assembly must therefore be followed exactly.

The following points must also be borne in mind:

The solids catcher is precisely aligned relative to the bowl in the manufactur-ing plant. In the case of subsequent dismantling of the solids catcher, it must be re-aligned using special tools to prevent

– the bowl from knocking against other parts and

Caution

suction effect. (Contact WS Service – see ‎5.9.

Before fitting the bowl parts, thoroughly clean all guide and contact surfaces and lock ring and grease or lubricate according to the instructions in ‎3.3.

When fitting the bowl parts, make sure that the “O” marks on all parts are aligned because only then will the parts be correctly seated by means of ar-resting pins and guide ribs.

Caution

Only use correctly rated, fully functional hoists.

Position hoists exactly to avoid damage to the guide surfaces and arresting pins when fitting or removing bowl parts.

– Select the low lifting speed of the hoist.

– Avoid diagonal pull!

– Do not use force to fit or remove parts.

Check gaskets for wear before fitting. Ensure that the gasket grooves and gaskets are clean. Fit only gaskets that are in perfect condition. After fitting, make sure that the gasket is not twisted and that the gasket is stretched equally around the groove.

If the plant has several separators, be careful not to interchange parts from different bowls (danger of imbalance!). The bowl parts are marked with the serial number or the last three digits of the serial number.

Always place bowl parts on a rubber mat or wooden pallet.

Handle all bowl parts with care.


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CAUTION!








Fig. 38

NOTE



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Fig. 39

NOTE



CAUTION!



CAUTION!


CAUTION!



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CAUTION!









Fig. 40




Fig. 41



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Fig. 42






Fig. 43



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Fig. 44



Fig. 45




Fig. 46


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Fig. 47




Caution




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Fig. 48



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Fig. 49


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5.2 Dismantling the feed and discharge connections

CAUTION:

To prevent accidents, do NOT loosen any part before the bowl has stopped completely!

Caution

The bowl is not at standstill until the gear sight glass is clear and the worm wheel has stopped rotating.

Disconnect the feed and discharge lines.

Unscrew the cap nuts of the dis-charge.

Remove the discharge.

Fig. 50

Unscrew the centripetal pump from the discharge with wrench size 46 (left-hand thread).

Fig. 51

Undo the Allen screws in the ring.

Fig. 52


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Remove ring.

Fig. 53

Screw on the two ring nuts.

Hang the lifter into the eye bolts.

Hang the shortened chains in the second hook “A”.

Fig. 54

Disconnect the ice water line.

Unscrew the screws 2 for fastening the hood 3.

Lift off the hood with the aid of the hoist.

Fig. 55


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5.3 Dismantling the bowl

CAUTION: To prevent accidents, do NOT loosen any part before the bowl has stopped completely!

Caution


Place bowl parts on a rubber mat or wooden pallet.

Replace worn gaskets in good time.

Loosen sealing cover by lightly tap-ping with the mallet against the han-dle of the annular wrench (left-hand thread).

Remove the cover.

Fig. 56

Remove the centripetal pump.

Fig. 57

Unscrew the spindle screw (left-hand thread).

Tool: Socket wrench

Fig. 58


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Force the bowl off the cone of the worm spindle (right-hand thread) and lift it out of the frame.

Place the bowl on a rubber mat or wooden pallet for further disman-tling.

Fig. 59

Remove threaded pins 2.

Screw pin spanner 1 with hex head screws onto the bowl lock ring (do not conceal “O” marks).

Tighten the hex head screws firmly.

Unscrew a threaded pin on the op-posite side of the pin spanner.

Fig. 60

Mounting the disk stack compressing device:

Place disc 41.4 on the bowl top.

Screw bolt 41.2 as far as it will go into the bowl bottom.

Insert hydraulic part 41.1 into the centering recess of the disc.

Screw on threaded ring 41.3 until its upper edge is flush with end thread of bolt 41.2.

Fig. 61


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To prevent damage to threads:

Attention!

Screw in threaded bolt completely.

Screw on threaded ring down to thread end.

If the threaded ring cannot be screwed down completely, then the piston and the cylinder of the compressing device are too far apart (note max. stroke, see sect. ‎5.8.

In this case:

Bring piston and cylinder into initial position:

– Loosen pressure relief screw 11 by two turns.

– Press the pump lever down as far as it will go.

– Screw on threaded ring 41.3 down to thread end.

Tighten screw connections of the compressing device.

Close pressure relief screw 11.

Compress the disc stack in order to facilitate loosening of the bowl lock ring.

Compression: 250 bar

Loosen the bowl lock ring by ham-mering against the handle of the pin spanner with a mallet (left-hand thread).

Screw the eye bolt on the opposite side of the pin spanner into the bowl lock ring.

Fig. 62

Lift off the bowl lock ring by means of the hoist.

If the lock ring is jammed:

Heat upper third of the bowl bottom with steam or hot water.

Caution

Do not use any other sources of heat, e.g. blow torch or welding torch.

Dismantling the compressing device:

Move pump lever of compressing device down as far as it will go to prevent it from jumping back.

Loosen pressure relief screw 11.

Unscrew threaded ring 41.3.

Remove hydraulic unit 41.1 and disk 41.4.

Unscrew bolt 41.2.

Fig. 63


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Lift the bowl top off the bowl bottom.

Tool: Lifting device

Fig. 64

Lift the distributor and disk stack out of the bowl bottom.


During this work step, the nozzles should remain fitted so that the segmental insert is not also lifted out.

Fig. 65

Unscrew the nozzles from the bowl bottom.

Remove the segmental insert from the bowl bottom.


Fig. 66

Turning the bowl bottom:

Screw the eye bolt as far as it will go into a nozzle bore.

Turn the bowl bottom using the hoist.

The bowl bottom is turned to: – flush out the bowl bottom – clean the bowl cone.

Fig. 67


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5.4 Replacing the nozzles with the hood closed

Unscrew inspection cover from the hood.

Unscrew nozzles using nozzle wrench.

By turning the wrench the nozzle is screwed into the sleeve of the wrench and can then be pulled out of the bowl bottom.

Fig. 68


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5.5 Assembling the bowl

Clean and dry the conical part of the spindle with a cloth.

Fig. 69

Clean the interior of the bowl hub with a cleaning rag to ensure proper location. Do not grease the conical parts!

Turning the bowl bottom:

Screw the eye bolt as far as it will go into a nozzle bore.

Turn the bowl bottom using the hoist.

Fig. 70

Insert the gasket in the groove in the bowl bottom.

Fit the segmental insert in the bowl bottom with the aid of a hoist.

Pay attention to correct positioning!


Fit 3 nozzles offset by 120° (for ex-act arresting).

Fig. 71

Insert gasket in the groove of the distributor.

Stack the disks on the neck of the distributor in numerical order begin-ning with No. 1.

Fig. 72


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Install the distributor together with the disk stack in the bowl bottom with the aid of the lifting device. Make sure that the arresting piece of the distributor catches into the groove of the bowl bottom. The "O" marks on both parts must be aligned.

Fig. 73

Clean and grease the contact and guide surfaces on the bowl bottom and bowl top (‎3.3.

Insert gasket into groove of bowl top.

Place bowl top onto bowl bottom. Make sure that the arresting cam of the bowl bottom catches into the groove of the bowl top. The "O" marks on both parts must be aligned.

Tool: Lifting device Fig. 74

Check and grease threads as well as contact and guide surfaces (see arrows) ‎3.3 .

Screw in bowl lock ring by hand (left-hand thread) until the "O" mark on the bowl lock ring is 2-3 cm apart from the "O" mark on the bowl bot-tom.

Fig. 75

Mounting the compressing device:

Place disc 41.4 on the bowl top.

Screw bolt 41.2 as far as it will go into the bowl bottom.

Insert hydraulic part 41.1 into the centering recess of the disc.

Screw on threaded ring 41.3 until its upper edge is flush with end thread of bolt 41.2.

Fig. 76

To prevent damage to threads:

Screw in threaded bolt completely.


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Screw on threaded ring down to thread end.

If the threaded ring cannot be screwed down completely, then the piston and the cylinder of the compressing device are too far apart (note max. stroke, see sect. ‎5.8 .

In this case:

Bring piston and cylinder into initial position:

– Loosen pressure relief screw 11 by two turns.

– Press the pump lever down as far as it will go.

– Screw on threaded ring 41.3 down to thread end.

Tighten screw connections of the compressing device.

Screw tight pressure relief screw 11.

Actuate the pump until the pressure gauge shows a reading of 250 bar.

Bolt 41.2 has not been screwed far enough into the distributor if

the max. pressure has not been reached.

grease discharges through the stroke limiting hole.

Remedy:

Loosen pressure relief screw 11 by two turns.

Screw in bolt 41.2 down to thread end.

Screw on threaded ring 41.3 down to thread end.

Screw tight pressure relief screw 11.

When compressing make sure that

– the groove of the bowl top catches over the arresting piece on the bowl bot-tom,

– the bowl top does not become twisted when lowering.

Tighten bowl lock ring by hitting with mallet against handle of ring span-ner until "O" mark alignment of bowl top and bowl lock ring is ob-tained.

Fig. 77

Caution

If the bowl lock ring can be screwed in by hand so far that the distance between the two “O” marks is less than 2 cm, the pressure in the disc stack has slackened.

A compensating disc must then be added.

If the distance between the “O” marks is more than 3 cm, check if all bowl parts are properly positioned and arrested.


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Dismantling the compressing device:

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 11.

Unscrew threaded ring 41.3.

Remove hydraulic unit 41.1 and disk 41.4.

Unscrew bolt 41.2.

Fig. 78

Place the bowl on the spindle cone by turning the tool clockwise.

Fig. 79

Firmly screw the spindle screw into the spindle. (left-hand thread).

Tool: Socket wrench

Fig. 80

Mount the centripetal pump.

Fig. 81


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Clean and grease threads on bowl top and in the centripetal pump chamber.

Screw on the centripetal pump chamber cover by hand and tighten it by hammering against the handle of the ring spanner (left-hand thread).

Tools: Ring spanner Mallet

Fig. 82


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5.6 Assembling the feed and discharge connections

Screw on two lifting-eye nuts.

Hang the lifting device into the lift-ing-eye nut.

Hang the shortened chains into the second hook "A".

Fig. 83

Insert gasket 3.

Place hood 1 onto the concentrate collector using the hoist.

Bolt the hood to the concentrate collector by means of hex head screws 2.

Connect ice water line.

Fig. 84

Place the disk onto the hood so that the two Allen screws in the disk are positioned over the respective ta-pholes of the hood. Do not tighten the screws!

Fig. 85

Screw centripetal pump A clock-wise into the ring until it hits stop.

Tool: Wrench SW 46

Fig. 86


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Firmly screw the two Allen screws into the hood.

Fig. 87

Place on the discharge and fasten it with cap nuts.

Fig. 88


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5.7 Fitting the nozzles

Fig. 89

Before fitting the nozzles, run up the bowl´(1 minute) and feed briefly with wa-ter.

Check that the nozzle bores are open.

Check the nozzle gaskets for damage.

Screw the nozzles into the bowl bottom. Tool: Nozzle wrench The front face of the nozzles must be flush with the outer wall of the bowl bot-tom. The screw-in slit is vertical. When looked at in the direction of rotation, the discharge hole is directed to the rear (see figure).

Attention!

The nozzles may not be screwed in deeper than specified and never as far as they will go. The consequence would be damage to the nozzle seat and heavy splashing of the quark during operation.


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5.8 Disk stack compressing device

Fig. 90

Operating principles The hydraulic part is connected with the bowl bottom via

– bolt 8 and

– threaded ring 12.

Operating sequence of pump:

pressing grease into pressure chamber 5,

piston 7 moves downwards due to the pressure,

the piston force is transferred to the bowl top via disc 9.

The disc stack is compressed.

Pressure must be gradually applied to the disk stack until the max. disk com-pression is attained.

Each pressure increase should be approx. 50 bar.

After each pressure increase, tighten bowl lock ring further.

When the max. disk compression has been reached, the "O" mark on the bowl lock ring must be approx. 1 -2 cm apart from the "O" mark on the bowl bottom.

Required compression: 250 bar ± 20 bar

Maximum pressure: 300 bar

3 Grease cartridge 4 Pump head 5 Pressure chamber 6 Hydraulic cylinder 7 Piston 8 Bolt 9 Disk

12 Threaded ring 13 Pressure gauge 14 Pressure relief screw


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Pump The pump produces a pressure of max. 400 bar. It consists of:

pump head

grease cartridge

filling device

Non-return valve

Filling the grease cartridge Cartridge filling: 450 g Use only WS K2R special grease.

Attention!

Actuate clamp piece 2 and pull the filling device 1 upwards.

Unscrew grease cartridge 3 from pump head 4.

Fill in grease.

Screw grease cartridge 3 into pump head 4.

Actuate clamp piece 2 and push filling device 1 into grease cartridge 3. The grease cartridge of the compressing device is filled with special grease be-fore shipment.

Malfunction If there is no build-up of pressure, check the following:

– Is the pressure relief screw 14 screwed in tightly?

– Is there enough K2R grease in the cartridge?

– Has piston 7 moved too far out of hydraulic cylinder 6 ?

If yes:

Unscrew pressure relief screw 14 a little way.

Force piston 7 back into hydraulic cylinder 6.

Re-tighten pressure relief screw 14 firmly.

Stroke limiting hole: If grease discharges through stroke limiting hole 10, bolt 8 and threaded ring 12 have not been screwed into their final positions; the stroke is too long.

Fig. 91


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5.9 Aligning the concentrate collector

Fig. 92

Attention!

Dismantling of the solids collector is normally not necessary. If, for certain reasons, the solids catcher is dismantled, it must be centred relative to the bowl spindle when fitted.

Unscrew the threaded plug from the neck bearing bridge 2 ‎9.3.1.

Fasten centering ring 1 on the neck bearing bridge by means of hex head screws 9.

Fit sleeve 4 on spindle 8. Unscrew puller screw 5 until the neck is seated on the spindle cone.

Fasten dial gauge 6 to sleeve 4.

Loosen hex head screws 7 using the solids catcher wrench.

Align the solids catcher so that the dimensional deviation “A” is maximum 0.4 mm around the complete periphery of the solids catcher.

Tighten hex head screws 7 and measure again. Correct if necessary.

Remove dial gauge 6.

Remove sleeve 4 by tightening puller screw 5.

Screw hex head screws 9 into puller holes 10.

Remove centering ring 1 by tightening hex head screws 9.

Screw the threaded plug into the neck bearing bridge 2 and ighten evenly and crosswise ‎9.3.1.


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Note Notes

Notizen Anotaciones

Notizen Notes Note


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6 Technical information

6.1 Separator bowl ....................................................................................... 94 6.2 Quark production using the standard process ....................................... 95 6.3 Standard quark processing line ............................................................. 96 6.3.1 Measuring probe .................................................................................... 97 6.4 Quark production using the thermo process .......................................... 98 6.5 Thermo quark processing line ............................................................... 99 6.5.1 Calculation of the quark yield standard process .................................. 101 6.5.2 Calculation of the required amount of skim milk (kg) .......................... 101 6.6 Determining the nozzles ...................................................................... 103 6.7 Installation features .............................................................................. 104


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6.1 Separator bowl

Fig. 93

Main components Function

Feed 1 Supply of start-up and safety water

Supply of coagulated milk.

Distributor 3 Acceleration of milk to angular velocity of bowl.

Supply and distribution of milk to rising channels of disc stack.

Rising channels 4 Entrance of milk into disc stack and distribution of milk in numerous disc interspaces.

Disc stack 5 Separation of coagulated milk into whey and quark by centrifugal force

Segment-holding insert 6

Prevents formation of quark deposits between the nozzles.

Nozzels 7 Continuous discharge of quark into the concentrate collector.

Centripetal pump 8 Converts kinetic energy into pressure.

Discharges whey from centripetal pump chamber foamfree and under pressure.

Discharge 9 Foamfree discharge of whey under pressure.


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6.2 Quark production using the standard process

The following approved heating processes are to be applied for pasteurization of the skim milk:

Short time heating

Temperature: 72oC

Holding time: 15 - 30 sec

Make sure that the temperature does not rise above 74oC

The result would be protein losses in the whey.

High temperature heating

Temperature: 86oC

Correct preparation of the vat milk is prerequisite for efficient quark production.

The pasteurized skim milk is cooled down to 28oC - 30

oC and then fed to renne-

ting tanks.

Dairy culture or a special fresh cheese culture should be used for acidifying the skim milk (low gas formation).

The amount of culture to be added depends on the:

acidification rate

acidification temperature

standing time of the vat milk

flavour to be obtained in the final product.

Normally are added:

0.5 % - 1 % culture and 1 cm3 liquid rennet per 100 l vat milk

Concentration: 1 : 10 000

0.5 % - 1 % culture and 1 cm3

dry rennet (dissolved in 250 cm3

water) per 1000 l vat milk.

Concentration: 1 : 100 000

After the addition of rennet the vat milk must be stirred thoroughly.

During the time of acidification (approx. 16 hours) of the vat milk the agitators must be shut off. Normally, the desired coagulation is achieved after this standing time.

The degree of acidity of the whey is then 25 - 8 SH (pH-value 4.55 - 4.5).

At this point the curd is efficiently stirred (at high agitator speed) for 15 minutes before the beginning of separation.

During the whole separating time the agitators in the tank must continue working at a low speed in order to obtain a constant dry matter content in the quark. By this means, uniform product is supplied to the separator.

The separating temperature should be at least 28 to 30oC.


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6.3 Standard quark processing line

Fig. 94

Component Function

Renneting tank 1 Storing vat milk.

Centrifugal pump 2 Conveying vat milk to balance tank 4 via reversible tubular strainer 3.

Tubular strainer 3 1st pre-straining of vat milk to remove coarse solid particles.

Balance tank 4 Intermediate storage of pre-strained vat milk, ensuring constant feed to separator.

Centrifugal pump 5 Conveying vat milk from balance tank to separator 8 via tubular strainer 6.

Tubular strainer 6 2nd re-straining of vat milk (fine solid parti-cles).

Feed control device 7 Automatic adjustment of feed rate via in-ductive flowmeter and pneumatic control valve.

Separator 8 Separating milk into quark and whey.

Tubular strainer 9 Pre-straining of safety water.

Quark funnel 10 Intermediate storage of quark for further treatment.

Positive displacement pump 11 Conveying the quark to silo 16 through cooler 12.

Quark cooler 12 Cooling the quark. Cooling medium: ice-water.

Cream tank 13 Storing cream for fat-enriched quark

Cream pump 14 Conveying cream to quark mixer 15.

Quark mixer 15 Mixing of quark and cream


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Silo 16 Storing quark before packing.

Positive displacement pump 17 Conveying quark to packing station.

A Safety water feed

B Whey discharge

C Ice-water feed

D Ice-water discharge

E Skim milk inlet

F to packing station

G Start-up water feed

H Start-up water discharge

6.3.1 Measuring probe

If a measuring probe is fitted in the separator environment, which, for example, controls a pump, it must be ensured that the probe functions in conjunction with the medium to be measured and transmits control signals.


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6.4 Quark production using the thermo process

In contrast to the standard process, the sweet and acidified skim milk is subjec-ted to a different heat treatment and temperature holding time.

Due to this a large portion of whey proteins in the skim milk is denatured and can be added to the quark thereby increasing the yield.

A higher quark yield is achieved as:

the whey proteins are denatured because of the heat treatment and the tem-perature holding time.

the whey proteins deposit on the casein during acidic coagulation of the milk.

During subsequent separation, these proteins discharge with the casein as low-fat quark. Consequently, the portion of proteins retained in the whey is less than that ob-tained during the standard process.

The skim milk is heated to 82 - 88oC and held at this temperature for 5 - 6 minu-

tes.

The exact heating temperature depends on the

milk quality

season

separator rating

Then the skim milk is cooled down to renneting temperature and fed to the ren-neting tanks at a temperature of 27 to 30

oC.

Normally are added:

0.5% to 1% special culture and 1.5 cm3

liquid rennet per 100 l of vat milk; concentration 1:10 000

0.5% to 1% special culture and 1 to 1.5 g dry rennet (dissolved in 250 cm3

water) per 1 000 l of vat milk; concentration 1:100 000

When a pH value of 4.5 is reached, the coagulated skim milk is heated to 60 - 63

oC, held at this temperature and then cooled to separating temperature of 40 -

45oC.

It is recommended that you contact Westfalia Separator before producing quark with the Thermo process.


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6.5 Thermo quark processing line

Fig. 95

Component Function Raw milk tank 1 Storing vat milk. Balance tank 2 Intermediate storage of vat milk,

ensuring constant feed to separator. Centrifugal pump 3 Conveyance of vat milk to separator 6 via

plate heat exchanger 4. Plate heat exchanger 4 Heating of skim milk to 82 - 88

oC

Cooling the skim milk to renneting tempera-ture (27 - 30

oC).

Tubular heating section 5 Holding the skim milk at pre-set tempera-ture (5 - 6 minutes).

Separator 6 Skimming of raw milk. Renneting tank 7 Stirring of coagulated skim milk,

ensuring homogeneous feed to separator 15.

Centrifugal pump 8 Conveyance of skim milk from renneting tank to balance tank 9

Balance tank 9 Ensuring constant feed to separator 15. Centrifugal pump 10 Conveying the quark to silo 16 through

cooler 12. Conveyance of skim milk from balance tank 9 to separator 15 via plate heat exchanger 11, tubular heating section 12 and reversible double strainer 13.

Plate heat exchanger 11 Heating the skim milk to 60 - 63oC.

Cooling of partial flow down to approx. 35

oC.

Precise adjustment of separating tempera-ture from 40 to 44

oC through mixing of par-

tial flows. Tubular heating section 12 Holding the skim milk at pre-set tempera-

ture (4 to 5 minutes). Double strainer 13 Pre-straining of skim milk. Tubular strainer 14 Pre-straining of safety water. Separator 15 Separation of coagulated skim milk into

whey and quark. Quark funnel 16 Intermediate storage of quark for further


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treatment. Positive displacement pump 17 Conveyance of quark to silo 22 via cooler

18. Quark cooler 18 Cooling of quark

Cooling medium: ice water. Cream tank 19 Storage of cream for the production of

fat-enriched quark. Mohno pump 20 Conveyance of cream to quark mixer 21. Quark mixer 21 Mixing of quark and cream. Silo 22 Storage of quark before packing. Positive displacement pump 23 Conveyance of quark to packing station. A Whole milk feed B Cream discharge C Culture and rennet addition D Safety water feed E Start-up water feed F Whey discharge G Ice-water feed H Ice-water discharge J to packing station


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6.5.1 Calculation of the quark yield standard process

MOMQ

MOMM

TT

)T(T100Q

Q = quark volume from the coagulated milk (kg)

TMM= dry matter of coagulated skim milk (%)

TMO = dry matter of whey (%)

TMQ = dry matter in low-fat quark (%)

Example:

TMM = 8.6 %

TMO = 6.1 %

TMQ = 18 %

kg95.201.618

1.6

8.6100Q

20.95 kg quark with a dry matter content of 18 % are obtained from 100 litres of skim milk.

6.5.2 Calculation of the required amount of skim milk (kg)

MOMM

MOMQ

TT

)T(TMM

MM = amount of skim milk (kg)

TMM = dry matter of coagulated skim milk (%)

TMM = dry matter of whey (%)

TMQ = dry matter in low-fat quark (%)

Example:

TMM = 8.6 %

TMO = 6.1 %

TMQ = 18 %

kg76.41.66.8

1.6

18MM

4.76 kg of skim milk are required to produce 1 kg quark with 18 % dry matter content.

The actual percentage of dry matter depends on the conditions prevailing in each dairy. Therefore, the above example cannot be set as a rule.


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Amount of skim milk required to produce 1 kg of quark based on the per-centage of dry matter in the quark (standard values).

Percentage of dry

substance in the

quark

abs. dry

Amount of skim milk

(kg) necessary to

produce 1 kg of

quark

(Standard Process)

Amount of skim milk

(kg) necessary to

produce 1 kg of

quark

(Thermo-Process)

17.0 4.19 3.79

17.5 4.38 3.98

18.0 4.76 4.37

18.5 4.85 4.45

19.0 5.05 4.65

19.5 5.23 4.83

20.0 5.43 5.03

20.5 5.62 5.22

21.0 5.80 5.40

21.5 6.02 5.62

22.0 6.20 5.80

22.5 6.38 5.98

23.0 6.57 6.17

23.5 6.76 6.36

24.0 6.98 6.58

The values in the above table show that the skim milk consumption per 1 kg of quark depends on the content of dry matter in the quark.

In addition to determining the yield theoretically, the actual amount of coagula-ted skim milk and the actual amount of the quark produced should be measured precisely.

Approximation of theoretically and practically obtained values will only be achie-ved by high accuracy of measurement.


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6.6 Determining the nozzles

The combination of nozzles and the nozzle bore diameters depend on:

throughput (milk volume / unit of time / l/h)

dry matter content in the coagulated skim milk

desired dry matter in the low-fat quark

The table of capacities below is based on quark with a solids content of 18 % abs. dry.

Nozzle capacity table

Throughput capacity

(coagulated skim milk)

l/h

Nozzle capacity

(Quark)

kg/h

Nozzle combination /

nozzle bore

mm

13 500 3 000 12 pieces x 0,7

Slight deviations from the stated values are possible as the ratio separator throughput to quark capacity depends on:

solids content of the treated skim milk

desired solids content in the quark

enlargement of the nozzle bore due to wear

Pre-straining the coagulated skim milk

Strainers must be installed upstream of the separator to prevent nozzle block-age:

Milk feed - tubular strainer 50 meshes/in (reversible, see section ‎6.3component, pos. 3)

Water supply-tubular strainer 70 meshes/in (see section ‎6.3component, pos.

9)


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6.7 Installation features

Cooling

The hood and concentrate catcher are cooled with chilled water to prevent the quark from depositing on the walls.

Inlet temperature: 1℃

Flow rate: 1,200 l/h

The cooling water first flows through the brake ring of the concentrate catcher and then the hood (series switching).

A pressure relief valve set to 2 bar is fitted in the catcher discharge line.

Attention

Discharge from the hood should be free and under gravity.

Specified water quality for chilled water:

Attention

Suspended matter: max. 10 mg/l

Chlorine ions: ≤ 100 mg/l

pH value: 6,5 - 7,5

Sealing water for slide-ring packing

Double-acting slide ring packings need sealing water to ensure correct function-ing. The sealing chamber fills the chamber between the bowl-side and gear-side slide ring, dissipates frictional heat and prevents foreign matter from entering the gear chamber.

Attention

Prior to starting the separator, sealing water must be supplied to prevent destruction of the slide rings due to overheating.

Sealing water pressure: Pmin.= 2.0 bar

Pmax.= 4.0 bar

Sealing water volume: Qmin.= 180 l/h

Sealing water temperature: Max. 60 oC at discharge

Water quality: Drinking water

The sealing water flow is monitored by a flow switch. The separator cannot be started until Qmin. has been exceeded.

During operation, the separator is shut down when Qmin is reached.

Even when a slide ring packing is well run in, it is normal when a little water drips through the leakage outlet.

Sterile air system

A slight overpressure is created in the frame pot by blowing in sterile air. This prevents bacterially contaminated foreign air from coming into contact with the quark.


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Specified water quality for circulation water:

Hardness: ≤ 12° dH up to 55° C separating temperature

≤ 6° dH above 55° C separating temperature

To convert the hardness values stated use the following equation:

Attention

Chlorine ions: ≤ 100 mg/l

pH value: 6,5 - 7,5

Vibration monitoring

During operation, the vibration behaviour of the separator is monitored by a vi-bration monitoring system. The vibration control works in two steps. An alarm is triggered when the vibra-tions are slightly increased. Production does not have to be interrupted. The separator must be checked at the end of production.

If the vibration levels reach the second stage, the bowl is filled via the safety wa-ter valve after a short delay. The motor is switched off at the same time. In this case, the separator must be checked immediately.

The limit values are:

– G1 = 4,5 mm/s

– G2 = 7 mm/s

Quark pump

Attention

When the solid pump fails, a configuration must be programmed to ensure switch-over to safety water.

Reason: Only low-viscous product flows off at the overflow of the quark hopper.


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Note Notes

Notizen Anotaciones

Notizen Notes Note


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7 Operation

7.1 General ................................................................................................ 108 7.2 Before each start-up ............................................................................ 108 7.3 Start-up ................................................................................................ 108 7.4 Operation ............................................................................................. 109 7.5 Shut-down ............................................................................................ 109 7.6 Shut-down “Emergency-Off”. ............................................................... 110


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7.1 General

Atten-tion!

Feed water to the bowl during start-up and braking as well as during inter-ruption of the milk supply to avoid nozzle blockage and uneven running of the bowl.

Severe unbalance can occur when:

– the bowl is not completely filled with liquid.

– Solids have deposited unevenly due to blocked nozzles. The unbalance is dampened when the bowl is fed with liquid during the brak-ing process.

Feed product and start-up or safety water to the separator via strainers to avoid nozzle blockage.

7.2 Before each start-up

Check that

all nozzles are open.

Fill the bowl with water and check if water comes out of all the nozzles in a jet. If not, the nozzles are partially blocked or damaged and must be cleaned or replaced.

Fig. 96

oil level is up to middle of sight glass (‎3.1).

separator is correctly assembled, especially the hex head screws on the hood and cap nuts on the discharge are tightened securely.

7.3 Start-up

Pressurize the sealing chamber with sealing pressure.

Open the water valve (approx. 6000 l/h).

Switch on the motor as soon as water discharges through the concentrate discharge.

Increase the water feed until a little water also discharges at the whey dis-charge.

Wait until the bowl has reached operating speed.

Before feeding the coagulated skim milk, disinfect the pipes from the tank to the separator and flush with water.

Feed ice water to the cooling chamber of the hood and the concentrate catcher.

Switch on the milk pump and close the water valve at the same time.


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7.4 Operation

Adjust constant-pressure valve in the whey line to approx. 0.5 bar below the overflow limit of the centripetal pump.

The discharging whey must be clear and not contain undissolved proteins. Should it still contain proteins, the hourly capacity must be reduced or another nozzle combination selected.

During operation, check concentration of discharge from time to time.

Uniform concentration of the low-fat quark can only be maintained when throughput capacity and solids content in the feed product remain constant Concentrate too thin: Increase throughput or insert smaller

nozzles. Concentrate too thick and turbid di-scharging whey:

Reduce throughput capacity or insert larger nozzles.

Sudden increase in concentration indicates that one or several nozzles are clogged. In this case avoid cleaning-in place after the operating process.

The separator must be stopped and cleaned manually.

7.5 Shut-down

Open the water valve and switch off the milk pump at the same time.

Regulate the water feed so that water flows off through the whey discharge during the run-down time.

Switch off the separator.

Attention

If required, the bowl can be automatically braked pneumatically. (max. braking pressure 2 bar)

The pneumatic brake is bled once the bowl has come to a standstill.

Do not loosen any part of the separator before the bowl is at a standstill.

Caution


Do not shut off the water feed until the bowl is at a standstill to avoid nozzle blockage and uneven running of the bowl.

Attention

If the separator is shut down for several days, the residual liquid in the bowl must be centrifuged out to avoid deposits and possible corrosion.

– Unscrew the nozzles,

– switch off the separator motor for about 1 minute.


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7.6 Shut-down “Emergency-Off”.

Shut-down (Emergency-Off) can be initiated: by vibration stage 2, by vibration stage 1 after 5 minutes, manually.

– Operate "Emergency-Off" key.

– Main motor off.

– Open the safety water valve.

– Milk feed valve closes.

– Pneumatic brake on.

At bowl standstill:

– Safety water closed.

– Pneumatic brake bled.

Caution

Do not loosen any part of the separator before the bowl is at a standstill. The bowl is not at standstill until the gear sight glass is clear and the worm wheel has stopped rotating.

When shut-down (Emergency-Off) is caused by vibration,

– Open and clean bowl before re-starting.

– Check if bowl is correctly assembled and check drive.


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8 Cleaning

8.1 CIP (cleaning-in-place) ........................................................................ 112 8.2 Bowl ..................................................................................................... 115 8.3 Concentrate catcher ............................................................................ 115 8.4 Upper section of the frame .................................................................. 115 8.5 Gear chamber ...................................................................................... 115 8.6 Before a long-term shut-down ............................................................. 116


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8.1 CIP (cleaning-in-place)

A cleaning unit has been developed for the automatic, chemical cleaning of quark separators and quark lines.

Cleaning with the central CIP unit is not admissible.

The cleaning unit has the advantage that cleaning can be carried out directly af-ter production.

With this unit, “one-way” cleaning can be carried out via a programmable con-trol.

Caution

Caution! Always feed liquid to the separator during shut-down to avoid inadmissi-ble bowl unbalance.

The corresponding valve switchings, steps and times for the cleaning are pre-set in the PLC of the manufacturer and must be optimised on site.. For further information, see the separate cleaning unit leaflet.

The following process information contains only general information on quark separators and apply for nozzle separators. Special attention should be paid to the project-specific documents.

Note:

– Detergents must not contain chlorine! Bowl parts of stainless steel will be attacked by chloride ions.

– Consult the detergent manufacturer for the temperature of the detergent.

Attention

Use only the recommended detergents.

1) Type of detergent

– Caustic: Caustic soda (NaOH) with a special additive or special detergent and antifoaming agent (see following table “Detergents”).

– Acid: Nitric acid HNO3

2) Concentration

– Caustic: 1.5 - 2 %

– Acid: 0,5 – max. 0.8

3) Temperature

– Caustic: 55 oC - 80

oC

– Acid: 50 oC , but never above 55

oC !

4) Throughput

– 25 % higher than the rated capacity of the separator.

5) Times

– The times specified in the following CIP flow chart can vary depending on the specific project. In addition, the guidelines of the DIN technical report “Dairy systems for cleaning and disinfecting using the CIP process” must be observed.


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Nozzle check!

Caution

After each cleaning cycle, a visual nozzle check is carried out for blockage and condition of the soldering joint!

In the case of excessively high temperatures and high concentrations of acid, the soldering joint between nozzle stone and nozzle holder can be chemically eroded and the bore of the nozzle stone prematurely washed out.

Attention

Nozzles whose soldering joint are damaged must be replaced!


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Fig. 97 - Subject to modification !


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8.2 Bowl The bowl must be dismantled and cleaned by hand when nozzles are

blocked, for example due to inadequate pre-straining of the coagulated milk.

For safety reasons, the bowl should be dismantled every 4 weeks to check the bowl threads and gaskets.

Take the gaskets out of the bowl parts before starting cleaning.

– Clean grooves and gaskets

– Replace damaged or very swollen gaskets immediately.

Thoroughly clean the individual disks and bowl parts with wooden scrapers and brushes.

Do not use metal scrapers and metal brushes!

Thoroughly clean, dry and grease the threads on the bowl bottom and bowl lock ring and all guide points (see ‎3.3).

Attention!

Make sure that all nozzles are open and no solids particles remain in the bowl so that the nozzles do not get blocked when operation is resumed.

8.3 Concentrate catcher

From time, the concentrate catcher has to be checked and cleaned if necessary.

8.4 Upper section of the frame

From time to time it is necessary to check the upper section of the frame in the area below the bowl and clean it, if necessary.

8.5 Gear chamber

When changing oil, clean gear chamber thoroughly with thin-bodied oil.

Be sure to remove all metal particles from walls and corners.

Do not use fluffy cleaning rags or cotton waste!


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8.6 Before a long-term shut-down

Before a long-term shut-down of the separator clean the separator thoroughly (see ‎8.2 and ‎8.4).

The clean bowl parts and all unvarnished machine parts should be wiped dry and greased to avoid corrosion.

The clean, greased bowl should be kept in a dry place.

To prevent the gaskets from getting brittle, keep them in a cool and dry room protected from dust and light.

Drain the lubricating oil and fill the gear chamber with corrosion-preventing oil, e.. SHELL Ensis oil 30, until the oil level is up to the middle of the sight glass.

Let the separator run without bowl for about 10 minutes to make sure that all gear parts are coated with the corrosion-preventing oil.

Then drain the oil.

Oil the upper spindle end by hand.

Check water shut-off devices for leakage. If necessary, disconnect water supply lines between faulty shut-off device and separator to avoid damage which may be caused by drip water.

Before re-starting the separator, fill the gear chamber with the lubricating oil specified on chapt. 3 until the oil level is up to the middle of sight glass. Then let the separator run without bowl for 10 minutes.


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9 Drive

9.1.1 Special risks of a separator ................................................................. 118 9.1.2 Safety precautions for maintenance and repair ................................... 120 9.2 Dismantling the vertical gear parts ...................................................... 125 9.2.1 Removal of ball bearings and worm .................................................... 128 9.2.2 Replacing the slide ring packing .......................................................... 129 9.3 Fitting the vertical gear parts ............................................................... 132 9.3.1 Assembling the neck bearing bridge ................................................... 133 9.4 Bowl height .......................................................................................... 134 9.4.1 Check ................................................................................................... 134 9.4.2 Re-adjustment ..................................................................................... 134 9.5 Removal of the horizontal gear parts ................................................... 136 9.5.1 Removing the motor ............................................................................ 136 9.5.2 Removing the fluid clutch ..................................................................... 137 9.5.3 Worm wheel shaft ................................................................................ 138 9.5.4 Removing the grooved ball bearing (motor side) ................................ 140 9.5.5 Removing the angular contact ball bearing (brake side) ..................... 140 9.6 Assembling the horizontal gear parts .................................................. 143 9.7 Pneumatic brake .................................................................................. 146


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CAUTION!








Fig. 98

NOTE



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Fig. 99

NOTE



CAUTION!



CAUTION!


CAUTION!



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CAUTION!









Fig. 100




Fig. 101



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Fig. 102






Fig. 103



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Fig. 104



Fig. 105




Fig. 106


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Fig. 107




Caution




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Fig. 108



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9.2 Dismantling the vertical gear parts

Remove bowl.

Undo the oil drain screw.

Drain the oil into the oil pan.

Fig. 109

Unscrew hex head screws from gear sight glass and

remove it.

Fig. 110

Loosen hex head screws in clamp plates of worm wheel.

Fig. 111

Slacken clamp plates until the worm wheel can be moved on the worm wheel shaft.

Move the worm wheel on the worm wheel shaft to the clutch side.

Fig. 112


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Unscrew cap nuts 1.

Remove gaskets 2.

Detach sterile air feed assembly 3.

Unscrew cap nuts 9.

Remove gaskets 8.

Fig. 113

For replacing seal 4 proceed as follows:

– Unscrew hex head screws 7.

– Force off ring using hex head screws M 8.

– Remove seal 4 from below.

Remove the following connections:

– sterile air sealing chamber

– pressure gauge line

– leakage line

– sterile air frame pot

Unscrew screw 3 from sleeve / spindle.

Unscrew hex head screws 2.

Force slide-ring packing cartridge 1 off the neck bearing bridge with hex head screws M 8.

Bolt spindle lifter 4 to the spindle with the aid of bowl spindle screw 5.

Pull out spindle together with neck bearing bridge.

Fig. 114


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To remove the neck bearing bridge, hold spindle in inverted position, up-per end down, and tap it against a wooden block.

Fig. 115

Unscrew the bottom bearing cap 5.

Take off gasket 4.

Unscrew bottom bearing threaded piece 3 and remove with sleeve 2 and bottom bearing pressure piece 1.

Fig. 116

If the bottom bearing housing 8 has to be replaced,

bend back tab washers 6,

unscrew hex head screws 7,

screw two screws 7 into the tapholes of the bottom bearing housing.

Press bottom bearing housing downwards by tightening the two hex head screws 7.


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9.2.1 Removal of ball bearings and worm

Remove the following components using a pulling device:

– ball bearing protection ring 7,

– angular contact ball bearing 9,

– bottom bearing housing 10,

– ball bearing protection ring 5,

– pendulum ball bearing 6.

Tap out cylindrical notched pin 4.

Pull off worm 3.

Pull off grooved ball bearing 1 and sleeve 2.

Then:

Press snap ring 8 out of the groove of bottom bearing housing 10.

Take angular ball bearing 9 out of the bottom bearing housing 10.

Fig. 117


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9.2.2 Replacing the slide ring packing

Fig. 118

The slide ring packing consists of the following items:

Pos. 3-Allen screw

Pos. 6-Slide ring

Pos. 7-Counter-ring

Pos. 8-Slide ring

Remove slide-ring packing cartridge (see also ‎9.2).

Unscrew Allen screws 5 and pull slide ring housing 4 off Slide ring housing cover 2.

The upper slide ring remains in the slide ring housing cover 2.

The lower slide ring remains in slide ring housing 4.

Lift out sleeve 1 with counter-ring 7.

Unscrew cylindrical screw 3.

Unscrew cylindrical screws 9.

Lift out slide ring 4 by hand.

Screw three wing screws 1 into the tapholes.

Tighten the wing screws evenly and push slide ring cage 3 out of slide ring housing 2.

Fig. 119


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Lift out slide ring 5 by hand.

Insert sleeve 2 with the small outer diameter into slide ring housing co-ver 3.

Mount disk 1.

Drive out slide ring cage 4 by ham-mering on disk 1.

Fig. 120

Fitting:

When fitting:

– make sure everything is perfectly clean,

– replace the gaskets,

– do not damage sealing surfaces and gaskets.

Fit sleeve 3 with the large outer diameter on slide ring cage 4.

Place disk 2 on sleeve 3.

Press the slide ring cage into slide ring cover 5 by hammering on disk 2.

Insert slide ring 1 into the slide ring cage by hand.

Note: It must be easy to move the slide ring axially.

Fig. 121


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Fit sleeve 2 with the large outer diameter on slide ring cage 3.

Mount disk 1.

Press in slide ring cage 3 by ham-mering on disk 1.

Insert the slide ring into slide ring housing 4 by hand.

Note: It must be easy to move the slide ring axially.

Fig. 122

Replace all gaskets in the counter-ring.

Bolt the counter-ring to the sleeve and mount in slide ring housing.


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9.3 Fitting the vertical gear parts When fitting the vertical gear parts proceed in reverse order of removal (‎9.2 ).

Important instructions: When installing the vertical gear parts bear in mind the following:

Thoroughly clean the gear chamber before installing the vertical gear parts (‎8.5 ).

Check ball bearings of worm spindle before re-fitting.

Attention!

Use only high-precision ball bearings (see list of spare parts).

For safety reasons, the ball bearings of the worm spindle must be replaced every 5 000 operating hours.

Before fitting grooved ball bearing, pendulum ball bearing, angular contact ball bearing and sleeve (grooved ball bearing), heat these parts in oil to approx. 80

oC.

Note!

The angular contact ball bearings 5 may be loaded axially in one direc-tion only.

They must be fitted so that the broad shoulder of the bearing inner rings is on top.

Faulty mounting will inevitably result in irreparable damage to the bear-ings.

Fig. 123

For re-assembly proceed as follows:

– Slide the heated angular contact ball bearings 5 onto the spindle.

– Slip snap ring 4 over the ball bearings.

– Let ball bearings cool down.

– Slide bottom bearing pressure housing 6 over the ball bearings.

– Press snap ring 4 into the groove of the bottom bearing pressure housing.

The worm spindle with fitted ball bearings must be able to be fitted on the up-per end of the spindle without hammering and be moved axially by hand. If this is not the case, smooth the inside of the bottom bearing housing with a fine emery cloth.

Attention!

When installing a new worm, the worm wheel assembly must be replaced at the same time.

When fitting the neck bearing bridge complete, make sure the gaskets do not get damaged.

Attention!

After installation of the vertical gear parts the height of the fitted bowl must be checked and re-adjusted if necessary (‎9.4 ).


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9.3.1 Assembling the neck bearing bridge

Insert sealing ring 2 into neck bea-ring bridge 3. Observe correct mounting position.

Insert pressure ring 1 into neck bea-ring bridge 3. Recesses of pressure ring must face the tapholes of the neck bearing bridge.

Insert neck bearing springs 5 into spring pistons 4.

Grease spring pistons.

Fig. 124

Screw threaded plug 7 with

– spring piston 4,

– neck bearing springs 5,

– and gasket 6 into the neck bearing bridge until they rest against pressure ring 1.

Align pressure ring 1 so that dimen-sion A=41.5 mm is attained bet-ween upper edge of neck bearing bridge and upper edge of pressure ring.

Tighten threaded plugs 3 evenly and crosswise.

Fig. 125


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9.4 Bowl height

The bowl height is correctly adjusted at the factory before the separator is shipped.

9.4.1 Check

Check the bowl height and re-adjust if necessary.

before commissioning the separator,

whenever replacing the vertical gear parts,

after fitting another bowl,

Pre-requisite to correct bowl height adjustment is that

the bowl is properly closed, (the "O" marks on bowl lock ring and on bowl bot-tom must be in line with each other.)

the hood is properly seated on the concentrate,

the fastening screws of the hood are tight,

The bowl height is correctly set when distance X between the concentrate catcher and bowl bottom is X = 2 mm.

If the distance deviates from the speci-fied dimension, the bowl must be re-adjusted.

Pay attention to height clearance of the centripetal pump (2-3 mm).

Fig. 126

9.4.2 Re-adjustment

Unscrew bottom bearing cap 3 and remove it with gasket 1.

Adjust bowl height by turning bottom bearing threaded piece 2. (1 turn = 2 mm):

Bowl is too low: Turn bottom bearing threaded piece clockwise. Bowl is too high: Turn bottom bearing threaded piece counter-clockwise.

Fig. 127


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Whenever changing the bowl height:

Check distance B between slide ring cover 1 and distance ring 2.

Dimension B must be 0.5 - 1 mm.

Fig. 128

Deviations

Distance smaller than 0.5 mm Distance greater than 1 mm

● Machine ring corresponding to deviation.

● Weld cams onto ring 2 (offset by 120

o), corresponding to the

deviation or ● Order new distance ring from the factory (state required height).

When assembling, the cams of the distance ring must point in direction of neck bearing!


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9.5 Removal of the horizontal gear parts

For removal of the horizontal gear parts proceed according to the following sec-tions.

Work on electric lines may only be carried out by a qualified electrician under observation of the safety regulations.

9.5.1 Removing the motor

Remove motor protecting hood.

Disconnect the motor and suspend it in hoist.

Unscrew hexagon nut 1 and take off lock washer 2.

By means of hoist lift off the motor 3 together with the cam hub.

Fig. 129

Unscrew Allen screw 1 and take off flange 2.

Fig. 130

Withdraw cam hub from motor shaft end using pulling device.

Fig. 131


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9.5.2 Removing the fluid clutch

After removing the motor:

Loosen hex head screw 1 using torque wrench.

Note tension of cup spring 3!

Unscrew hex head screw, remove washer 2 and cup spring.

To remove fluid clutch from cone of worm wheel shaft use tool 4.

Fig. 132


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9.5.3 Worm wheel shaft

Remove bowl.

Loosen oil drain screw and drain oil into oil cup.

Fig. 133

Unscrew hex head screws from gear sight glass and remove sight glass.

Fig. 134

Loosen hex head screws in clamp plate of worm wheel.

Fig. 135

Slacken clamp plate until worm wheel can be moved on the worm wheel shaft.

Push worm wheel to the clutch side.

Fig. 136


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Take off compressed air connection 1 for pneumatic brakes.

Unscrew hex head screws 2 on the ventilator cowl.

Unscrew ventilator cowl with pneu-matic brakes.

Fig. 137

Unscrew hex head screw 1 from the worm whel shaft.

Tools: Torque wrench 8 Hexagon socket wrench (SW 22 mm)

Pay attention to tension of cup springs!

Remove centering disk 2 and cup springs 3.

Fig. 138

Pull brake drum 1 off the cone of the worm wheel shaft.

Tool: Pulling device 40

Fig. 139

Unscrew Allen screws from bearing cover.

Remove holder and proximity switch. Tools: Torque wrench 8 Hexagon socket (SW 8 mm)

Fig. 140


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Place on wooden block.

Drive out worm wheel shaft towards brake side including ball bearing, nut and bearing cover until the ball bearing has been loosened from the seat on the motor side.

Fig. 141

Pull out the worm wheel shaft by hand; while doing so, hold worm wheel to prevent damage to gear teeth.

Take worm wheel with clamp plates out of the gear housing.

9.5.4 Removing the grooved ball bearing (motor side)


Remove lock washers 2.

Remove bearing cover 3 together with – sealing ring 4, – gasket 5.

Drive out ball bearing 6 from the gear-chamber side by placing a brass mandrel on the inner ring of the ball bearing.

Fig. 142

9.5.5 Removing the angular contact ball bearing (brake side)

Lift tab of washer 12 out of groove of nut 13.

Unscrew nut.

Remove tab washer 12.

Withdraw angular contact ball bea-ring 11 from worm wheel shaft using a commercial pulling device.

Fig. 143


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Note Notes

Notizen Anotaciones

Notizen Notes Note


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Fig. 144 – Horizontal gear parts


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9.6 Assembling the horizontal gear parts

Note: For reasons of safety, replace ball bearings of worm wheel shaft every 1000 op-erating hours.

Fit angular contact ball bearing 11 onto worm wheel shaft 7. Make sure that the filling groove of the bearing faces outwards to the bearing cover.

Fit tab washer 12. After having tightened nut 13, bend one tab of washer into a groove of the nut. Ensure that the tab does not extend beyond the outer diameter of the nut.

Fit grooved ball bearing 23 into the bearing housing 39 (clutch side). Fit bearing cover 26 and tighten with hex head screws 28.

Install worm wheel with clamp plates 8 into gear housing so that the clamp plate with toothing is directed towards the clutch side.

Attention!

The worm wheel has been balanced in the factory as complete assembly. To avoid unbalance, the clamp plates and the toothed rim must, therefore, not be twisted on the wheel body and component parts must not be re-placed individually.

When the toothed rim is worn, always replace the worm wheel with clamp plates. Replace the worm of the spindle at the same time.

Introduce the worm wheel shaft 7 into the separator frame from the brake side, and slide on the worm wheel.

Place a hard wooden block against the worm wheel shaft and tap it lightly with a hammer until the angular contact ball bearing 11 is tightly seated in the housing.

Install bearing cover 16 with inserted sealing ring 15 and gasket 14.

Bolt tight the bearing cover and holder A of the proximity switch B with Allen screws 18 and lock washers 17.

Required torque: 45 Nm

Tools: Torque wrench, hexagon socket SW 8 mm

Re-adjust proximity switch 2 with the aid of adjusting ring 1.

Fig. 145


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Fig. 146 – Horizontal gear parts


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Slide the worm wheel to the brake side up to the shoulder of the worm wheel shaft (the position of the toothed rim relative to the worm is then correct), then clamp it tightly onto the worm wheel shaft by evenly tightening the screws into the two clamp plates crosswise. Required torque: 45 Nm. Tools: Torque wrench Hexagon socket SW 17

Mounting the grooved ball bearing (motor side):

Remove bearing cover 26.

Pull grooved ball bearing 1 evenly against the shoulder of the worm wheel shaft using – device 2 and – hex head screws 3.


Remove the mounting tool 2.

Fig. 147

Replace bearing cover 26 with fitted radial packing rings 25 and gasket 14 and tighten evenly with hex head screws 28 (lock washers 17 placed under-neath).

Before installing the fluid clutch 29 and the brake pulley 19:

– apply a thin film of grease to the tapered ends of the worm wheel shaft. Then grease, clean and wipe dry the tapered ends with a rag.

– Clean the inside of the hubs of the fluid clutch and brake pulley carefully.

Slide the fluid clutch and brake pulley onto the shaft ends and bolt tight with hex head screws 22, centering disks 21 and cup springs 20.

Required torque: 150 Nm Tools: Torque wrench, hexagon socket SW 22 mm


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When fitting the motor, note:

The distance between claw hub 1 and fluid clutch 2 must be 4 mm.

Check the distance after fitting

– - a different motor,

– - a different claw hub,

– fluid clutch

– another worm wheel shaft.

Fig. 148

If readjustment becomes necessary:

Displace claw hub on the motor shaft.

Re-drill motor shaft for threaded pin.

Fill:

gear chamber as described in section 3.

Check:

direction of rotation of the bowl

spindle speed with a hand tachometer (‎4.4).

Running-in:

When using new gear parts (worm wheel, worm), let the separator run for approx. one hour without bowl. While running in the gear parts, switch the motor on and off several times.

9.7 Pneumatic brake

Fig. 149


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Dismantling

Remove compressed-air connection 2.

Unscrew hollow screws 3.

Remove guard 4.

Remove pipe 5.


Remove fan cover 10.

Screw threaded pipe angle and T-type hose coupling 6 out of compressed-air cylinder 8.

Remove caps 7.

Unscrew compressed-air cylinder 8 from brake housing 9.

Unscrew Allen-screws 12 and take out brake bolt 13.

If the brake housing is to be removed, unscrew cylindrical pin 11.

Assembly

For assembly of the brake proceed in the reverse order of dismantling.


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Note Notes

Notizen Anotaciones

Notizen Notes Note


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10 Fluid clutch

10.1 General ................................................................................................ 150 10.2 Checking the oil level: .......................................................................... 150 10.3 Filling in oil ........................................................................................... 151 10.4 Type of oil ............................................................................................ 152 10.5 Dismantling .......................................................................................... 153 10.6 Re-assembling ..................................................................................... 155


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10.1 General The fluid (Turbo) clutch

– ensures power transmission between motor and gear, – gradually accelerates the bowl to its rated speed, – while protecting the gear and the motor against undueload.

By means of an oil filling, power is transmitted from the primary wheel (driven by the motor shaft) to the secondary wheel (fitted to the worm wheel shaft). The fluid clutch has to be filled with the appropriate quantity of oil (‎10.2) (to make sure that the bowl reaches its rated speed within the prescribed start-ing period - ‎4.4).

If the fluid clutch contains

too small an amount of oil: too much oil: D starting time of bowl too long D starting time of bowl too short D excessive slippage D excessive load on motor D clutch temperature too high

Change the oil in the fluid clutch

– after approx. 5 000 operating hours,

– preferably during an inspection of the separator (while replacing the bearings of the worm spindle and of the worm wheel shaft).

For a new oil filling of the fluid clutch, you need: (standard values) about 6,75 liters of oil for a motor speed of n = 1 455 rpm about 6,5 liters of oil for a motor speed of n = 1 745 rpm To determine the definite quantity of oil needed, refer to the instructions given under ‎10.2.

Attention

Be sure only to use the oil stated under ‎10.4. The oil quantity is correct when, during start-up, the max. current con-sumption of the motor is 1.8 to 2 times the rated current.

10.2 Checking the oil level: The oil level in the fluid clutch has to be checked

– prior to the first start of the separator, – after each re-filling of oil, – once a week, in order to detect oil losses. – Important: Check the oil level only while the clutch is cold!

Brand-new separator: The mark of oil level plate 1 must be flush with the lower rim of bore 2 (the oil level will then be up to the lo-wer rim of bore 2).

When replacing the clutch, the existing oil level plate becomes invalid. Re-adjust the oil level plate as stated under "Separator with replacement clutch"

Fig. 150


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The required quantity of oil can be roughly determined with the aid of the oil le-vel plate. .

For checking the oil level, proceed as follows: Separator with original clutch (fitted at the factory):

Unscrew the ventilation grid to uncover the oil level plate.

Turn the fluid clutch until threaded plug 2 can be unscrewed without oil esca-ping.

Unscrew the threaded plug using the pin spanner.

Then turn the clutch until

– the lower rim of the bore for the threaded plug

– is flush with the mark of the oil level plate (‎10.2). In this position, oil should just escape from the bore.

If this is not the case, re-fill oil and check the starting current, referring to section ‎10.3.

Separator with replacement clutch:

After replacement of the clutch, the existing oil level plate becomes invalid!

The oil quantity is correct when, during start-up, the max. current consumption of the motor is 1.8 to 2 times the rated current.

If an exact measurement of the motor current is not possible, the oil level can be checked by measuring the speed of the worm wheel shaft. While the separator motor is under nominal load, the speed should be

– approx. 1 455 rpm at 50 Hz,

– approx. 1 745 rpm at 60 Hz.

If the starting current and the speed respectively are much higher than these values, the clutch contains too much oil.

If, however, the measured values are lower, the clutch contains too small an amount of oil.

Once the correct oil level is reached, re-place the oil level plate accordingly.

10.3 Filling in oil Fill the clutch with oil before installing it (for the required quantity of oil, refer to ‎10.1)

Thead in the screw plug fitted with a new gasket, and tighten firmly.

The correct oil quantity is reached when, during start-up, the max. current consumption is 1.8 to 2 times the rated motor current.

If oil has to be added, proceed as follows:

Unscrew the ventilation grid to uncover the oil level plate.

Turn the fluid clutch until threaded plug 2 can be unscrewed without oil esca-ping.

Unscrew the threaded plug using the pin spanner.

Re-fill oil through the bore (e.g. using a commercially available funnel and a hose).

Thead in the screw plug fitted with a new gasket, and tighten firmly.

Re-fit the ventilation grid.


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10.4 Type of oil For filling the fluid clutch use only

steam turbine oil TDL 32 (WS part-no. 0015-0050-090 )

This oil complies with the following specification deviating to some extent from

DIN:

Designation Lubricating oil TDL 32 - DIN 51515 (steam turbine oil with additives giving increased protection against corrosion and increased resistance to aging.

Kinematic viscosity 32 ± 3,2 mm2/s (cSt) at 40 oC

Density / 15 oC max. 0,900 g/ml

Pour point ≤ 9oC

Open flash point ≥ 210oC to Cleveland

Corrosive effect on

– copper degree of corrosion 2 - 100 A3 according to DIN 51759

– steel degree of corrosion 0 - A according to DIN 51585

Aging characteristics Increase of the neutralization number after 1000 h max. 2,0 mg KOH/g oil according to DIN 51587

The following branded oil meets this requirement: Shell Turbo Oil T 32.

Attention

Steam turbine oils TDL 32 of other brands may be used provided they comply with the above specification.

Each clarifier is supplied with an amount of TDL 32 oil which is sufficient for one filling.


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10.5 Dismantling

Normally, the fluid clutch has to be sent to the factory when needing repair. Only then can perfect repair of the clutch be assured. Upon request, a replacement clutch can be supplied.

If, in exceptional cases, the clutch has to be dismantled at site:

Begin with checking sealing ring 6 for possible replacement.

Fig. 151

Removing sealing ring 6

Undo screws 4 together with lock washers 3.

Remove cover 3.

Force off sealing ring 6 with a screwdriver.

Replace the sealing ring if its sealing lip is no longer soft and elastic.

Fig. 152

Removing sealing ring 18 and ball bearing

Unscrew threaded plug 1 together with gasket 2.

Let the oil drain.

Unscrew hexagon nuts 12.

Remove screws 16 together with lock washers 13.

Fig. 153


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Attention

Thread two screws 16 into the ta-pholes of primary wheel 11.

Detach the primary wheel from clutch casing 15 (primary and sec-ondary wheel remain together). Prior to dismantling, mark the fol-lowing parts: – clutch casing 15 and – primary wheel 11.

(Do NOT offset them when re-installing - risk of imbalance)

Fig. 154

Separate primary wheel 11 from secondary wheel 7 by hitting with a rubber hammer against the hub of secondary wheel 7 (ball bearing 8 will remain in primary wheel 11).

Fig. 155

Knock ball bearing 8 out of primary wheel 11 using a mandrel and a hammer.

Fig. 156

Removing sealing ring 18 and ball bearing 20

Undo screws 22 together with the lock washers.

Remove cover 3.

Force off sealing ring 18 with a screwdriver. Replace the sealing ring if its sealing lip is no longer soft and elastic.

Knock ball bearing 20 out of the clutch casing using a mandrel and a hammer.


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10.6 Re-assembling

For re-assembling the fluid clutch pro-ceed in reverse order of dismantling. Special attention should be paid to the following:

Torques: A = 150 Nm

B = 95 Nm

C = 46 Nm

D = 80 Nm

Fig. 157

Moisten the sealing rings.

Screw bolt B into disk A and apply it against the sealing ring.

Press sealing ring 18 into cover 21 by hitting lightly against bolt B.

Screw bolt B into disk A from the other side and press sealing ring 6 into cover 5 in the same way.

Fig. 158

Insert spacer ring 19 into clutch cas-ing 15.

Insert spacer ring 10 into primary wheel 11.

Fig. 159


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Note:

The chamfered edges of the rings must catch into the grooves. (Only then are the spacer rings se-cured against axial creeping.)

Fig. 160

Press ball bearing 20 into the clutch casing and ball bearing 8 into the primary wheel. Check that the ball bearings pressed into the spacer rings have a perfectly tight seat. Otherwise replace the spacer rings.

Insert gasket 9 into the groove of the primary wheel.

Fasten cover 5 to the primary wheel by means of hex head screws 4 with their lock washers.

Insert gasket 23 into the groove of the clutch casing.

Fasten cover 21 to the clutch casing by means of Allen screws 22 and their lock washers.

Press secondary hub together with secondary wheel 7 into the clutch casing. (The contact surfaces of the sealing rings must be in perfect condition in order to prevent leakage.)

Insert gasket 14.

Press the primary wheel onto the secondary hub so that the marks on the primary wheel and on the clutch casing are in line.

Bolt the two parts together.

Attention

After re-assembly, the clutch has to be re-balanced!

Prior to installing the clutch, fill it with oil.


1315-9001-060 / 0804

11 Trouble shooting

11.1 Mechanical function ............................................................................ 158 11.2 Possible causes for inefficient separation ........................................... 161


1315-9001-060 / 0804

11.1 Mechanical function

Fault Possible causes Remedies

The bowl does not come up to

rated speed or takes too long to do

so (see ).

Motor is incorrectly connected. See wiring diagram.

The fluid clutch does not contain

enough oil or clutch is leaky.

Re-filling oil ( 10.3)

Renew sealing rings.

The bowl is placed too low and rubs

against concentrate collector.

Adjust bowl to proper height ( 9.4)

The bowl is placed too high.

Liquid seeps through too big a gap

between bowl bottom and concen-

trate collector and flows into upper

section of frame, resulting in slow-

ing-down of the bowl.

Adjust bowl to proper height ( 9.4).

Clean upper section of frame.

Frame drain is clogged.

Liquid or dirt has collected in the

upper section of frame.

Clean frame drain with siphon and

upper section of frame.

Clamp plates not tight enough;

worm wheel slips on shaft.

Tighten long hex head screws on

worm wheel evenly and firmly.

Tighten crosswise, by single turns,

with a torque of 45 Nm.

Water feed is opened too wide. Adjust water volume to approx.

1500 l/h (see 7.3).

The bowl speed drops during oper-

ation.

Nozzle bores are worn out, or noz-

zles are leaky due to damaged

gaskets.

Install new nozzles.

Replace the gaskets.

The fluid clutch does not contain

enough oil.

Re-filling oil ( 10.3).

Motor speed drops during opera-

tion.

Inspect motor and line voltage.

The bowl comes up to rated speed

too quickly.

Motor pulls too high a starting cur-

rent.

The clutch contains too much oil. Check oil level ( 10.2).

Reduce oil contents.


1315-9001-060 / 0804


Uneven run of the separator. One or several nozzles are

clogged. The separated solids have

deposited unevenly in the bowl.

Shut down the separator via

„Emergency-Off” ( 7.6):

• Main motor off.

• Safety water valve opens.

• Milk feed valve closes.

• Pneumatic brake ON.

Thoroughly clean the bowl by hand.

Bowl is not properly assembled or,

if plant has several separators,

parts of different bowls may have

been interchanged.

Assemble bowl properly (see 5.5).

Tension of disc stack has slack-

ened.

Make sure bowl lock ring is

screwed on tightly (see 5.5).

Check number of discs.

If necessary, add a spare disc or

compensating disc.

Bowl is damaged and, therefore out

of balance.

Send bowl to factory or authorized

factory repair shop.

Do not attempt to make your own

repairs.

Never weld or solder.

Bowl is made of heat-treated steels.

Neck bearing springs are fatigued

or broken.

Replace all 9 neck bearing springs.

Ball bearings are worn. Replace damaged bearings.

IMPORTANT!

When replacing, use only the high

precision ball bearings as specified

in the Parts List.


1315-9001-060 / 0804


Uneven run of the clarifier (cont’d.) Gear parts are in bad condition as a

result of

1. normal wear,

2. premature wear caused by

a) lack of oil *

b) oil of too low a viscosity *

c) metal abrasives present in the

lubricating oil due to the following

possible causes:

- viscosity of oil is too low,

- oil has not been changed in time,

- gear chamber has not been

cleaned,

d) replacement of one gear part

only, instead of both parts.

* ) in general, recognized by blue

tempering colour of gear parts.

Clean gear chamber thoroughly

(see 8.5).

Replace damaged gear parts 9.3

and 9.6

Change oil (chapter 3).

If necessary, change oil more often.


1315-9001-060 / 0804

11.2 Possible causes for inefficient separation

Fault Possible causes

Insufficient concentration Temperature of coagulated skim milk too low. Acidity degree too low (pH value too high). Skim milk has not been renneted. Feed rate too low. Nozzle diameter too large. Nozzle gaskets are damaged, see list of parts - bowl. Gaskets of the segment–holding insert are damaged, see list of parts -bowl.

Whey is not pure Feed rate too high. Nozzles are clogged; solids content of quark increases. Rising channels in disc stack are clogged Vat milk: ● separating temperature too low, ● rennet concentration too low, ● acidity degree too low or too high, ● pasteurization temperature too high, ● skim milk heated for too long.


1315-9001-060 / 0804

Note Notes

Notizen Anotaciones

Notizen Notes Note


1315-9001-060 / 0804

12 Lubrication and maintenance

12.1 Lubrication chart .................................................................................. 164 12.2 Maintenance schedule ......................................................................... 165 12.2.1 Guide to ordering spare parts .............................................................. 166 12.2.2 Use of non-genuine spare parts .......................................................... 167


1315-9001-060 / 0804

12.1 Lubrication chart

Fig. 161

No. in Fig. Lubricant Frequency of lubrication Amount of

lubricant

Lubrication point

DIN ISO pro anno nach Betriebsstd.

1 Klüber Grease

KSB 8 when necessary 10 cm

3 Threads and

fittings

2 Klüber Grease

KSB 8 before each as-

sembly

150 cm3

Threads and

sliding surfaces of

bowl

3 Roller bearing

grease K3K 2 1 500 20 cm

3 Neck bearing

springs and spring

pistons

- Roller bearing

grease K3K 2 1 500 10 cm

3 Manually-operated

parts (brake bolt,

valves, etc)

5 Lubricating oil

CLP 220

DIN 51502

CC 220 2 500 5 500 cm3

Gear chamber

6 Steam turbine oil

TDL 32

DIN 51515

10 000 6 250 cm3

Fluid clutch

7 Roller bearing

grease K3K

according to

manufacturer’s

instructions

according to

manufacturer’s

instructions

Motor bearings


1315-9001-060 / 0804

12.2 Maintenance schedule

every operating hours

every

250 500 1500 3000 5000 10 000 OPERATIONS Week 1/4

year

1/2

year

1

year

LUBRICATION CHART D First oil change after first start-up or after re-

placing worm wheel and worm. Thorough cleaning of gear chamber.

Check oil level of gear chamber. D

D Oil change and thorough cleaning of the gear chamber.

D

D Lubrication of hand-operated parts such as brakes, valves, etc*

D

whenever dismantling Grease threads, and guide and contact surfaces of bowl parts ( 3.3)

whenever dismantling

according to manufacturer’s instructions Grease motor ball bearings. accord. to manufact. instruct.

MAINTENANCE CHART

CLEANING Dismantle bowl and clean it thoroughly. 4 weeks

Clean interior of frame and concentrate collector.

4 weeks

INSPECTION D Remove and check bowl gaskets.

Clean gasket grooves and check for corro-sion.

D

D Check starting time and speed of bowl spin-dle.

D

D Check neck bearing springs and spring

pistons.

D

Check thickness of brake linings. D

D Check oil level of fluid clutch. 4 weeks

D Check toothing of worm gear through in-spection hole (after removing the gear sight glass

D

Bowl inspection.*

Check threads of lock rings for erosion and

corrosion.

D

whenever dismantling Check diameter of nozzle bores. whenever dismantling

REPLACEMENTS D Replace neck bearing springs .

D Replace oil in fluid clutch.

D Replace roller bearings of worm spindle.

D Replace roller bearings of worm wheel shaft.

* Keep to the maintenance intervals even if the operating hours have not been reached.


1315-9001-060 / 0804

12.2.1 Guide to ordering spare parts Rapid and correct supply of spare parts can only be guaranteed if your order includes the following information:

Separator model

see separator nameplate

e.g. MSD 200-01-076

Serial-No. see separator nameplate

e.g. 1724-035

Designation see order-specific parts catalogue

Part-No. see order-specific parts catalogue

The following information is required only when ordering bowl parts:

Bowl S/N

since it may be different from the serial number of the machine.

It can be found on the bowl lock ring, bowl bottom and bowl top.

Information only required when ordering spares for pump and pump connec-tion parts.:

Type and number of pump

see pump nameplate

The information must be complete in order to avoid incorrect deliveries.


1315-9001-060 / 0804

12.2.2 Use of non-genuine spare parts

Use only genuine spare parts from Westfalia Separator. The use of non-genuine parts leads to: – safety risks – less durability of these parts – reduced availability of the separator – increased maintenance requirement.

Fig. 162

NOTE

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.


1315-9001-060 / 0804

Note Notes

Notizen Anotaciones

Notizen Notes Note


1315-9001-060 / 0804

13 Datasheet

13.1 Datasheet............................................................................................. 171


1315-9001-060 / 0804

Note Notes

Notizen Anotaciones

Notizen Notes Note


1315-9001-060 / 0804

13.1 Datasheet

This datasheet contains data important fort he safe operation and assembly of the separator. It is only valid when no datasheet in accordance with DIN/EN 12547 is enclosed with the complete set of documentation.

NOTE

Subject to modification! If a datasheet conforming to DIN/EN 12547 is enclosed with the complete set of documentation, the datasheet in the instruction manual is null and void.

Minimum lifting capacity of hoist for removing the bowl kg 600 Kg

Minimum height of hoist for removing the bowl: 3 410mm

Overall height of the separator. 1 796mm

Bowl speed: 4 800 1/min (See also separator nameplate)

Starting time: ca.10 min

Run-down time: ca.45 min

Motor data: (see motor name-plate)

Oil quantity for gear chamber: 5,5 L

Westfalia Separator AG

Take the Best – Separate the Rest

A company of mg technologies group Westfalia Separator AG ● Werner-Habig-Straße 1 ● D-59302 Oelde (F.R. Germany)

Tel.: +49 (0) 25 22 / 77-0 ● Fax: +49 (0) 25 22 / 77-24 88 ●

http://www.westfalia-separator.com/● mailto:[email protected]

http://www.westfalia-separator.com/

mailto:[email protected]

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