Instruction Manual and Part List MSD 90
Instruction Manual and Part List MSD 90
Instruction Manual and Part List MSD 90
Mechanical Separation
Division
No.: 1225-9001-040
Edition: 0900
Designation: Skimming Separator
with self-cleaning bowl
Model: MSD 90-01-076
2 Westfalia Separator AG
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Westfalia Separator AG 3
Fig. 1
Westfalia Separator
D-59302 Oelde (F. R. Germany)
Model S/N
Built in ø in mm
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• Take special care when carrying out operations marked with this
symbol –
• Instruction manual
in this manual
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1 Safety precautions 9
2 Installation 25
2.1 Transport................................................................................................28
2.2 Installation..............................................................................................28
3 Lubrication 31
4 Motor connection 35
5 Bowl 39
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6 Technical information 65
7 Operation 73
8 Cleaning 81
9 Drive 85
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8 Westfalia Separator AG
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1 Safety precautions
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Fig. 2
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Fig. 3
Under the influence of the centrifugal forces, separation of the liquid mixture
and/or ejection of the solids particles takes place most rapidly.
The specifically heavier components are displaced to the bowl periphery, whe-
reas 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.
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1.5.1 Assembly
• If the plant has several centrifuges,
be careful not to interchange parts
of different bowls since each bowl
has been balanced individually.
The bowl parts are marked with the
serial-number of the machine or with
the last three digits of the serial-
number.
Fig. 4
Fig. 5
Fig. 6
Fig. 7
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Fig. 8
Fig. 9
Fig. 10
1.5.2 Electrical appliances
• The governing accident prevention
regulations apply for the electrical
appliances and installations.
• The frequency and voltage of the
power supply must correspond to
the machine specifications.
• Carry out potential equalization.
• Observe legal regulations; e.g. in
the EU:
– Low-voltage guideline 73/23/EWG
– Electro-magnetic compatibility
89/336/EWG.
Fig. 11
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Fig. 12
Fig. 13
Fig. 14
Fig. 15
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Fig. 16
Fig. 17
1.5.4 Operation
• Refer to chapter »operation«.
• Note nameplate. The values for
– bowl speed
– density of the heavy liquid,
– density of solids (centrifugally dry)
are max. values and must not be ex-
ceeded.
Fig. 18
Fig. 19
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Fig. 20
Fig. 21
Fig. 22
Fig. 23
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Fig. 24
Fig. 25
1.5.5 Shut-down and »Emergency-Off«
• For shut-down refer to the chapter
"operation".
Fig. 26
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Fig. 27
Maintenance and repair work may only be carried out by the customer to
the extent as described in this instruction manual.
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.
We, therefore, recommend in your own interest to have your separator in-
spected by our service engineers at regular intervals. Such inspections will keep
your separator working reliable and prevent undesirable shut-downs.
Before maintenance and servicing:
• switch off all electrical appliances
via the main switch,
• secure installation against unin-
tended re-starting with locking de-
vices.
Fig. 28
Fig. 29
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Fig. 30
Fig. 31
Fig. 32
Fig. 33
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Fig. 34
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1.6 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 the risk of damage.
At the initial stage pit-shaped corrosion is generally caused by chlorine ions.
Depending on the stressing of the part, pit-shaped corrosion can result in crack-
shaped corrosion.
Possible formation of pit-shaped cor-
rosion.
Fig. 35
Fig. 36
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1.7 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 bowl material.
Contact your nearest Westfalia Separator representative for a thorough exami-
nation. Information on the nature of the damage can be provided by photos,
plaster casts or lead molds.
Fig. 37
The surfaces most susceptible to erosion are:
1) the bottom of the distributor, the rising channels and the ribs,
2) the centripetal pump (cavitation),
3) all surfaces in the area of the solids discharge ports,
4) the nozzles.
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Fig. 38
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Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
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2 Installation
2.1 Transport................................................................................................28
2.2 Installation..............................................................................................28
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Load on foundation:
static N = 18 000 N
dynamic horizontal on each foot 200 N
vertical on each foot 390 N
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Fig. 41
2.1 Transport
• Suspend the separator as shown in figure.
• Never attach rope to eye bolt on motor.
• To prevent rope from slipping, wind it twice around the crane hook.
When lowering the separator, make sure it touches down gently
2.2 Installation
When installing the separator, make sure that sufficient room is available to
mount and remove the motor (see dimensioned drawing).
If several separators are installed, the distance from center-to-center of the se-
parators must be observed, see dimensioned drawing.
Do not install a shut-off valve in the frame drain and do not connect this frame
drain to a piping system. The operating water must be able to discharge freely
into a sewer or sludge tank, e. g. via a funnel. Otherwise it will rise into the up-
per section of the frame, resulting in slowing down of the bowl. It can also seep
down through the neck bearing into the gear housing and damage the gear.
For mounting and removing the bowl a 500 kg hoist or slewing pillar crane is re-
quired.
If possible use flexible tubes for connecting the feed and discharge lines of the
separator to the fixed pipe lines so that vibrations occurring during start-up and
slowing-down of the machine are absorbed.
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Fig. 42
• Screw bolts 6 into the four mounting blocks of foundation frame 8 as far as
they will go.
• Embed the foundation frame in the floor 7 so that the mounting blocks of the
frame protrude from the floor by about 5 mm.
• Level the foundation frame so that the cams are horizontal and anchor it in
conformity with local regulations (e.g. by means of approved anchor bolts).
• By means of flanges 3 and screws 2, fasten feet 4 with fitted-on rubber cush-
ions 1 to separator frame.
• Lift the separator onto the bolts of the foundation frame.
• Tighten threaded pins 5 with a wrench.
• The dynamic forces of each individual foot act as common torque on the
foundation.
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Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
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3 Lubrication
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The gear oil designated "Separator lubricating oil CLP 220" ( WS part-no. 0015-
0014-080) which we have subjected to extensive tests meets the above re-
quirements and should be used.
Fig. 43
During operation the oil level must never be allowed to sink below the
middle of the sight glass; refill oil when necessary.
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Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
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4 Motor connection
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Fig. 44
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Make sure that the bowl reaches its rated speed within the starting time
and that this speed is maintained during operation.
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Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
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5 Bowl
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The bowl parts are marked with the serial number of the machine or the last
three digits of the serial number.
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* Attention: After replacing this part, the complete bowl must be rebalanced!
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Fig. 46
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Fig. 47
Fig. 48
Fig. 49
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Fig. 50
Fig. 51
Fig. 52
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• Before opening the bowl, release the brakes by turning the two handles in
clockwise direction.
• Handle bowl parts with care.
• Replace worn gaskets immediately.
• For tools refer to chapter 13 - list of spare parts
• Loosen centripetal pump chamber
lock ring by lightly tapping with the
mallet against the handle of the an-
nular wrench (left-hand thread).
Fig. 54
Fig. 55
Fig. 56
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Fig. 57
Fig. 58
Fig. 59
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In this case
• Bring piston and cylinder into initial position:
– loosen pressure relief screw 8 by two turns,
– press the pump lever down as far as it will go,
– screw on threaded ring 3 down to thread end.
• Tighten screw connections of the compressing device.
• Screw tight pressure relief screw 8.
• To facilitate loosening of the bowl
lock ring compress the disc stack
with the compressing device.
Pressure: 230 - 250 bar
Fig. 60
Fig. 61
Fig. 62
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Fig. 63
• Set the compressing device upright and tighten the centripetal pump chamber
lock ring firmly.
• By actuating the hydraulic part 2 force bowl top off the bowl bottom.
• After loosing the bowl top hang the
hook of hoist into the eye bolt.
• Remove hydraulic part and threaded
ring.
• Lift off the bowl top.
Fig. 64
Fig. 65
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Fig. 66
Fig. 67
IMPORTANT:
Make sure that the sealing lip of the
sliding piston does not get dam-
aged.
Fig. 68
Fig. 69
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Fig. 71
Fig. 73
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Fig. 74
Fig. 75
Fig. 76
Fig. 77
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Fig. 78
Fig. 79
Fig. 80
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Fig. 81
Fig. 82
Fig. 83
Fig. 84
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Fig. 85
Fig. 86
If the threaded ring cannot be screwed down completely, then the piston
and the cylinder of the compressing device are too far apart.
n this case:
• Bring piston and cylinder into initial position.
– loosen pressure relief screw 8 by two turns,
– press the pump lever down as far as it will go,
– screw on threaded ring down to thread end.
• Tighten screw connections of the compressing device.
• Screw tight pressure relief screw 8.
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If the disc stack pressure is too low, an additional disc must be inserted.
If the maximum pressure is not attained and grease flows out of the stroke limit-
ing hole, then bolt 4 has not been screwed far enough into the bowl bottom.
The compressing device is only ready for use again when bolt 4 and threaded
ring 3 have been brought back into the position as described above.
• Tighten bowl lock ring by hitting with
mallet against handle of wrench un-
til "O" mark alignment of bowl
bottom and bowl lock ring is ob-
tained.
Fig. 88
Fig. 89
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Fig. 90
Fig. 91
IMPORTANT!
Do not use force.
Do not hammer against the wrench
handle.
Fig. 92
Fig. 93
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Fig. 94
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Fig. 95
Fig. 96
Fig. 97
Fig. 98
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Fig. 99
Fig. 100
Fig. 101
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Fig. 102
Installation
• Insert gasket (with its narrow side
facing the bowl top) into the clean
groove of the bowl top.
• Using a smooth piece of hard wood,
hammer the gasket evenly into the
groove until its sealing surface pro-
trudes from surface A by not more
than 1 mm.
Fig. 103
IMPORTANT!
It is possible that a new gasket will be
too small.
If the gasket is too small, soak it for
about 5 min. in a water bath at a tem-
perature of 70 - 80°C (160 -175°F).
The gasket will then return to its origi-
nal size.
Fig. 104
Fig. 105
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Fig. 106
• Push sleeve a of the wrench to-
gether with the pins into the bores of
the bowl valve.
• Tighten collar nut b.
• Unscrew bowl valve from bowl bot-
tom using socket wrench 1.
Fig. 107
If the valve piston 2 remains stuck in
the bowl bottom while pulling out the
valve proceed as follows:
• Screw wrench 3 (for valve piston)
into the valve piston.
• Pull valve piston out of the bowl
bottom by means of the wrench.
Fig. 108
5.8 Installation of bowl valves
For installation proceed in reverse order of removal.
NOTE:
• Moisten gaskets.
• Grease the threads.
• Screw in the valve as far as it will go. However, do not screw it in too tightly.
• The front face of the valve housing must be flush with the outer wall of the
bowl bottom.
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Fig. 109
Operating principles
The pump presses grease at a high pressure into pressure chamber 18.
The increase in pressure in the pressure chamber displaces piston 21 in relation
to hydraulic cylinder 20.
The hydraulic part (piston, hydraulic cylinder) is bolted securely to the bowl bot-
tom by means of bolt 4 and threaded ring 3.
When the pressure increases in pressure chamber 18, piston 21 is displaced
downwards.
The force produced is transferred to the bowl top via the disk 5. The disc stack
is compressed.
Required pressure: 230 - 250 bar
Pump
The pump produces a pressure of max. 400 bar. It consists of:
• pump head
• filling device
• non-return valve
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• Actuate clamp piece 13 and push filling device 12 into grease cartridge 14.
Fill the grease cartridge only with WS special grease K2R.
Malfunctions
If there is no build-up of pressure, the following must be checked:
• Is the pressure relief screw 10 screwed in tightly?
• Is there enough K2R grease in the grease cartridge?
• Has piston 21 travelled too far out of hydraulic cylinder 20?
If yes,
• loosen pressure relief screw 10 and
press piston 21 without pressure
back into the hydraulic cylinder 20.
• Then screw in pressure relief screw
10 again tightly.
Fig. 110
• If grease discharges through stroke limiting hole 17, bolt 4 and threaded ring
3 are not screwed into their correct end position; the stroke is too long.
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6 Technical information
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Fig. 111
6.1 Operating principles of the bowl
The separator is equipped with a self-cleaning disc type bowl.
A hydraulically movable sliding piston opens and closes the bowl.
The product enters the bowl through the "soft-stream inlet system". This ar-
rangement ensures gentle and turbulence-free product feed into the rising
channels of the disc stack.
The milk or the whey flows through feed (1) into the bowl and is separated in the
disc stack (6) into skim milk and cream.
By means of centripetal pumps (4 and 5) both components are discharged fo-
amfree and under pressure and conveyed to outlets (2 and 3).
The separated solids collect in the solids holding space (7) from where they are
ejected periodically through ejection ports (8).
Solids ejection is initiated by a control unit.
The product is fed into and discharged from the centrifuge by means of a closed
system of pipes.
The rated capacity is adjusted by means of a flow constrictor in the feed line.
Skim milk and cream are discharged under pressure.
The pressure in the skim milk discharge line (3) can be adjusted by means of a
constant-pressure valve and read off on a pressure gauge.
A regulating valve and a flowmeter in the cream discharge line (2) serve to ad-
just the cream.
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Fig. 112
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Bowl open
2 Injection chamber for operating
water (bowl valve)
3 Closing chamber
4 Piston
5 Feed hole -operating water
(bowl valve)
6 Bowl valve
7 Valve piston
8 Gasket
9 Bowl gasket
10 Drain hole for operating water
(closing chamber)
11 Solids holding space
13 Solenoid valve
14 Solids ejection ports
Fig. 113
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1 Water feed
2 to separator
3 Air connection
Fig. 114
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Fig. 115
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Technical data:
Solenoid valve Type 281 281
Part-Number 0018-5870- 0018-5947-
610 610
Pipe connection R 3/4in 1/2in
Voltage V DC 24 24
Power consumption: pull-in W 8 8
operation W 8 8
Duty cycle % 100 100
Frequency of operation /h 1000 1000
Type of enclosure IP 65 65
Pressure range bar 0,5 - 16 0,5 - 16
0
Temperature: medium C + 100 + 100
0
ambient C + 55 + 55
Cable entry Pg 9 9
(coupler socket)
Maintenance
The solenoid valves do not require special maintenance.
Locating electrical faults
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7 Operation
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7.1 General
This chapter gives general instructions for operating the separator. However,
operation of the respective machine depends on the control unit used and the
arrangement of the valves.
The individual process may necessitate changes in the operating procedure.
Refer also to the instruction manual of the respective control unit.
7.2 Before start-up
check that
• brake is released by turning handle clockwise.
• oil level is up to middle of the sight glass.
• hex head screws for fastening the hood and cap nuts for fastening the feed
and discharge housing are tightened securely.
• hand shut-off valves are opened in the supply lines for:
– operating water
– compressed air
• cream valve is open.
• timers on the control unit are set according to the instructions in the control
unit manual to suit the respective processing conditions.
• metering unit is adjusted (see sect. 7.5.1).
• compressed air on the pressure reducer is adjusted to 4-5 bar.
7.3 Starting
• Switch on main switch on control unit (position I):
The LED "control unit ON" flashes to signal that the control unit is ready for
operation.
The buttons "product", "partial ejection" and "total ejection" are not released
until the signal "motor in operation" is on (see LED in motor mimic diagram).
• Start motor.
After a pre-set delay time of 10 minutes, closing water is supplied automati-
cally; the bowl closes.
• After a further two minutes water can be circulated as generally practiced in
dairies.
• Switch over from water to product.
Actuate "separation" button on the control unit.
• Adjust discharge pressure and cream volume as follows:
– Throttle skim milk discharge pressure with constant-pressure valve and si-
multaneously adjust cream valve to desired flow rate.
– First throttle constant-pressure valve in skim milk discharge until slight over-
flow occurs.
To check the overflow, unscrew blind nut on hood.
The pressure indicated by the pressure gauge at the moment of overflow is
to be considered as maximum pressure.
– Reduce air pressure on pressure reducer to such an extent that a pressure
0.3 to 0.5 bar lower than the maximum pressure is indicated on the pres-
sure gauge.
It is only necessary to adjust the constant-pressure valve to operating pressure
when starting for the first time.
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Fig. 116
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1 Water feed
2 to centrifuge
3 Air connection
Fig. 117
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Fig. 118
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1 Water feed
2 to centrifuge
3 Air connection
Fig. 119
In the case of failure of the control unit or defective solenoid valves, the centri-
fuge can be manually controlled as follows:
Partial ejection
Open closing-water valve and the solenoid valve for filling water manually by
means of adjusting screw and screwdriver.
Open opening-water valve briefly (approx. 1 sec.).
After partial ejection leave closing-water valve open.
Total ejection
Stop product pump.
Open closing-water valve and the solenoid valve for filling water with a screw-
driver.
Open opening-water valve until the ejection noise has subsided.
Then close opening-water valve and fill-up valve; leave the closing-water valve
open.
After speed recovery, i. e. reaching operating speed re-start product pump 1 mi-
nute after total ejection.
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Do not loosen any part before the bowl has stopped completely!
• Note that the bowl has not stopped moving until the gear sight glass is clear
and the worm wheel has ceased rotating.
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8 Cleaning
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Bear in mind that bowl parts of stainless steel will be attacked by chlorine.
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8.2 Bowl
It is not normally necessary to dismantle and clean the self-cleaning bowl upon
completion of the separation process, provided that cleaning-in-place has been
adequately performed while the bowl was still moving.
How often it is necessary to clean the bowl by hand is dependent on the nature
of the product and can only be determined by tests.
• However the bowl should be dismantled once a month for the purpose of che-
cking and manual cleaning.
Never use metal scrapers or metal brushes for cleaning the discs and
bowl parts!
• Remove gaskets from the bowl parts.
• Clean grooves and gaskets to prevent corrosion.
• Replace damaged or swollen gaskets.
• Carefully clean the small holes for feed and discharge of the operating water
in bowl bottom as well as the piston valve to assure trouble-free performance
of the solids ejection process.
• Clean and wipe dry guide surfaces and threads of bowl parts and grease
them (see 3.2).
• Spindle cone and inside of bowl hub should be oiled and then wiped clean
and dry with a smooth rag.
• Re-assemble bowl immediately after cleaning.
8.3 Upper section of frame
• From time to time, the inside of the
upper section of the frame has to be
cleaned in the area below the bowl.
• After removing the bowl (see 5.3),
place a protective hood e.g. a com-
mercially available container over
the spindle to prevent wash liquid
from seeping into the drive and ren-
dering the lubricating oil unservice-
able.
Fig. 120
Never aim a water jet directly at the separator for the purpose of cleaning.
Clean it by hand with a sponge or cloth.
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9 Drive
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Fig. 121
Fig. 122
Fig. 123
Fig. 124
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Fig. 125
Fig. 126
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Fig. 128
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• 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 ap-
prox. 80 oC.
Note that
• 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 inner ring of
the bearing is on top.
• Faulty mounting will inevitably result
in damage to bearings.
Fig. 129
• When fitting the neck bearing bridge complete, make sure the gaskets do not
get damaged.
After installation of the vertical gear parts the height of the fitted bowl
must be checked and re-adjusted, if necessary (9.3).
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Fig. 131
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Fig. 132
• Note that after tightening the neck bearing protection cap, the distance ring 3
and, hence, the ball bearing 2 will be under pressure until the spring column
in the bottom bearing is compressed by the weight of the bowl.
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Fig. 134
9.3.2 Adjusting
• Unscrew bottom bearing cap 2 and
remove gasket 1.
• Adjust bowl to correct height by
turning bottom bearing threaded
piece 3 (1 revolution = 2 mm).
• Bowl is too low,
turn bottom bearing threaded piece
clockwise.
• Bowl is too high,
turn bottom bearing threaded piece
counter-clockwise.
Fig. 135
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Fig. 137
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Fig. 138
Fig. 139
Fig. 140
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Fig. 141
9.4.3 Worm wheel shaft
• Loosen oil drain screw and
• drain oil into oil cup.
Fig. 142
• Unscrew hex head screws from
gear sight glass and
• remove sight glass.
Fig. 143
• Loosen hex head screws in clamp
plate of worm wheel.
Fig. 144
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Fig. 145
• Unscrew hex head screws 3 (wash-
ers 2) and
• remove fan cover 1.
• Unscrew hex head screw 4 from
worm wheel shaft.
• Note tension of cup spring!
• Remove centering disc 5 and cup
spring 6.
Tools:
Torque wrench
Hexagon socket (SW 24 mm)
Fig. 146
• Remove brake pulley 1 from cone of
worm wheel shaft using device 2
(brake pulley).
Fig. 147
• Unscrew Allen screws from bearing
cover (brake side)
• Remove holder and proximity
switch.
Tools:
Torque wrench
Hexagon socket (SW 8 mm)
Fig. 148
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Fig. 150
9.4.5 Angular contact ball bearing (brake side)
• Lift tab of washer 8 out of groove of
nut 9.
• Unscrew grooved nut using pivoted
hook wrench.
• Remove tab washer 8.
• Withdraw angular contact ball bear-
ing 7 from the worm wheel shaft us-
ing a commercially available pulling
device.
Fig. 151
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Fig. 152
Note:
For reasons of safety, replace ball bearings of worm wheel shaft every 10 000
operating hours.
• When fitting the angular contact ball bearing 7 onto the worm wheel shaft,
make sure that the filling notch of the bearing faces the bearing cover.
• Install tab washer 8 and grooved nut 9.
– After having tightened nut 9, 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.
• Install worm wheel assembly with clamp plate 21 so into gear housing that the
screw heads of the clamp plate are directed towards the brake side.
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 rotated on the wheel body and component parts must not be re-
placed individually.
When the toothed rim is worn and needs replacement, the entire worm
wheel assembly 20 with clamp plates must be replaced. The worm of the
worm spindle should be replaced at the same time.
• Introduce the worm wheel shaft 20 into the separator frame from the brake si-
de, and slide on the worm wheel.
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• Place a hard wooden block against the worm wheel shaft and tap it lightly with
a hammer until the angular contact ball bearing 7 is tightly seated in the hous-
ing.
• Install bearing cover 12 with inserted sealing ring 11 and gasket 10.
• Bolt bearing cover 12 and holder 13 of proximity switch 14 together by means
of Allen screws 16 and 18 (with lock washers 19 underneath).
Required torque: 45 Nm.
• Re-adjust proximity switch 1 with the
aid of adjusting ring 2.
Fig. 153
Fig. 154
• Replace bearing cover 27 including felt rings 28 and gasket 26 and tighten
evenly with hex head screws 29 (lock washer 30 placed underneath).
• Move worm wheel towards brake side until it rests against shoulder of worm
wheel shaft. This will ensure proper positioning of the toothed rim with refer-
ence to the worm.
• Fasten worm wheel 21 securely on the worm wheel shaft 20 by tightening the
screws in the two clamp plates evenly and crosswise.
Required torque: 45 Nm
• Before installing the fluid clutch and the brake pulley:
– apply a thin film of grease to the tapered ends of the worm wheel shaft.
Then clean and wipe dry the tapered ends with a rag.
– Clean the inside of the hubs of the fluid clutch and brake pulley carefully.
• The fluid clutch and the brake pulley must be firmly clamped to the worm
wheel shaft, accomplished by tightening the hex head screws 1 of the clutch
and brake pulley with the torque wrench.
Required torque: 150 Nm
• Be sure to fit cup springs 3 under the disks 2.
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• Fill gear chamber with oil specified in chapter 3 until oil level is slightly above
middle of sight glass.
• Check spindle speed with a hand tachomter and check direction of rotation of
bowl (see 4.3).
• To run in new gear parts (worm wheel, worm) let the separator run - without
bowl - for about one hour.
During this time switch the motor on and off several times.
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10 Fluid clutch
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10.1 General
The fluid clutch (Turbo Clutch) gradually brings the bowl to its rated speed, eli-
minating premature wear on gear parts and on motor.
The motor power is transmitted by means of a closed oil circuit between a pri-
mary wheel driven by the motor shaft and a secondary wheel driving the worm
wheel shaft of the separator.
The oil level in the fluid clutch must be up to the mark of the oil level indicator
plate, to ensure that the bowl comes up to its rated speed within its starting time
(see sect. 4.3).
When less oil filled in, slippage in the clutch will be too great and starting time
of the bowl too long. If the clutch contains too much oil, the starting time of the
bowl will be too short, resulting in overload of motor and gear.
The oil in the clutch has to be changed every 10 000 working hours. It should be
changed when the ball bearings of the worm spindle and of the worm wheel
shaft are being replaced.
The clutch requires
approx. 6,3 litres of oil when using a 1455 rpm motor
approx. 5,25 litres of oil when using a 1745 rpm motor.
For checking the oil level, proceed according to the instructions in sect.
10.2.
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Fig. 157
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The following branded oil meets this requirement: SHELL Turbo Oil T 32.
Steam turbine oils TDL 32 of other brands may be used, provided they
have an open flash point according to Cleveland of approx. 210 oC which
is contrary to DIN 51515.
Each separator is supplied with an amount of TDL 32 oil which is sufficient for
one filling.
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10.5 Dismantling
As a rule, the fluid clutch must be sent
to the factory for repair.
This ensures perfect functioning of the
repaired clutch.
If required, a replacement clutch can
be provided.
If, in exceptional circumstances, the
fluid clutch must be dismantled on site,
first check the sealing ring 6 and re-
place it if necessary.
Fig. 158
Fig. 159
Fig. 160
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Fig. 162
Fig. 163
Fig. 164
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10.6 Re-assembly
For re-assembly of the fluid clutch,
proceed in reverse order of disman-
tling.
The following should be kept in mind:
Fig. 165
Fig. 166
Fig. 167
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Fig. 168
• Press ball bearing 20 into clutch casing and ball bearing 8 into primary wheel.
Check if the ball bearings pressed into the spacer rings have an absolutely
tight fit. If this is not the case, the spacer rings have to be replaced.
• Apply some oil-resistant sealing compound (Atmosit or Kermon) to oil retain-
ing ring 21. Then
• fasten ring to clutch casing with screws 22. Be sure to fit lock washers.
• Insert gasket 9 in groove of primary wheel 11.
Then fasten cover 5 to primary wheel with screws 4. Be sure to fit spring was-
hers.
• Press secondary hub with secondary wheel 7 into clutch casing.
The surfaces contacting the sealing rings 18 and 6 must be perfectly smooth
to ensure oil-tightness of the fluid clutch.
If necessary, re-polish contact surfaces.
• Place Teflon packing cord 14 on
sealing surface of clutch casing as
shown in figure.
• Make sure cord ends are crossed.
To keep the cord in its place, coat it
with grease. Sealing surfaces of
primary wheel and clutch casing
must be in perfect condition; they
must not be coated with a sealing
compound.
Fig. 169
• Press primary wheel on secondary hub so that the marks on primary wheel
and on clutch casing are in line.
Then screw primary wheel and clutch casing together.
After repair the clutch has to be rebalanced.
• After re-installing the clutch, fill with oil.
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11 Trouble shooting
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a) lack of oil ①
If necessary, change oil more often.
b) oil of too low a viscosity, ①
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,
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Fig. 170
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116 Westfalia Separator AG
Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
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Fig. 171
No. in Lubricant Frequency of lubrication Amount of Lubrication
Fig. lubricant point
DIN ISO per year after operating
hours
1 Klüber Grease when necessary 10 cm3 Threads and
KSB 8 fittings
2 Klüber Grease before each as- 150 cm3 Threads and
KSB 8 sembly sliding surfaces
of bowl
3 Roller bearing 2 1 500 20 cm3 Neck bearing
grease K3K springs and
spring pistons
4 Roller bearing 2 1 500 10 cm3 Manually-
grease K3K operated parts
(brake bolt, val-
ves, etc)
5 Lubricating oil CC 220 2 500 5 500 cm3 Gear chamber
CLP 220
DIN 51502
6 Steam turbine oil 10 000 6 250 cm3 Fluid clutch
TDL 32
DIN 51515
7 Roller bearing according to according to Motor bearings
grease K3K manufacturer’s manufac-
instructions turer’s in-
structions
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* Keep to the maintenance intervals even if the operating hours have not been reached.
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Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
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13 Parts list
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Note
Notes
Notizen
Anotaciones
Notizen
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Note
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To ensure correct delivery when ordering parts, please state the following:
• Model of separator see name–plate
e.g. MSD 90–07–076
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Fig. 172
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32 1233–1277–000 1 Gasket
33 0019–6142–400 4 Allen screw DIN 912 M 10x20
34 0019–6105–400 8 Allen screw DIN 912 M 6x12
35 0007–2208–750 2 Gasket DIN 11851 G 25
36 1165–1183–000 1 Plug
37 0007–2320–750 1 Gasket 45x55x5
38 0007–2580–750 1 Gasket 42x2.5
39 0013–0404–400 2 Cap nut DIN 1587 M8
40 0007–3062–840 1 Gasket 625.5x666x19
41 0007–2113–750 1 Gasket 94x104x6
42 1167–1045–000 1 Pipe connection
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Fig. 173
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Fig. 174
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Fig. 175
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Fig. 176
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Fig. 177
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* * The part number depends on the motor speed as well as on the bowl speed given on the name-plate
of the separator
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Fig. 178
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1 – 1 * Cam flange
2 0019–6971–150 8 Hex head screw DIN 933 M 12x35 8.8
– 0019–1141–300 8 Threaded insert M 12x18
3 0026–0772–170 8 Spring washer DIN 137 B 12
4 0004–2913–830 1 Sealing ring 105x130 BAFS
5 0026–0182–170 1 Spacer ring ANS 160/163x26
6 0011–6021–400 1 Grooved ball bearing DIN 625 6021 M/C4
7 0019–6518–150 36 Hex head screw DIN 931 M 10x70 8.8
8 – 1 * Clutch casing ø470
9 0004–2385–858 1 Packing cord ø1x1400 mm
10 0026–0771–170 36 Spring washer DIN 137 B 10
11 0013–0279–150 36 Hexagon nut DIN 934 M 10 – 8
12 – 1 * Primary wheel ø470
13 0026–0180–170 1 Spacer ring AN 140/143x24
14 0007–2944–830 1 Gasket 140/3
15 0011–6018–400 1 Grooved ball bearing DIN 625 6018 M/C4
16 – 1 * Secondary hub with secondary ø 425
wheel
17 0004–2912–830 1 Sealing ring 90x110
18 – 1 * * Sealing ring cover
19 0019–6903–150 8 Hex head screw DIN 933 M 8x20 8.8
– 0019–1139–300 8 Threaded insert M 8x12
20 0026–0770–190 8 Spring washer DIN 137 B8
21 0007–1741–280 1 Gasket DIN 7603 A 22x29
22 1166–1161–000 1 Hex head collar screw M 24x1.5x16
– 0019–1142–300 2 Threaded insert M 24x1.5x18
23 0007–1740–280 4 Gasket DIN 7603 A 18x24
24 0019–1490–000 2 Threaded plug M 18x1.5x15
– 0019–1137–300 2 Threaded insert M 18x1.5x18
25 3158–3287–010 1 Oil retaining ring ø119/192x4.5
26 0019–2234–030 8 Cheese head screw DIN 84 AM 5x16 4.6
27 0026–0750–170 8 Lock washer DIN 7980 5
28 0019–1551–090 1 Oil fill plug
– 0019–0861–000 2 Threaded plug M 18x1.5x15
* When this part needs replacement, the complete clutch must be returned to the factory for repair.
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Fig. 179
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Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
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Fig. 180
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Fig. 181
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Fig. 182
1 1238-7765-010 1 Hood
2 0007-1905-750 1 Gasket 45x4
3 0001-0963-820 1 Sight glass disk 55x10
4 0013-0406-400 4 Cap nut DIN 1587 M 12
5 0004-2364-758 1 Packing cord 8x8x3300
6 0019-6971-300 8 Hex head screw ISO 4017 M 12x35
7 0026-0165-400 4 Washer DIN 433 13
8 0019-7668-400 4 Stud
9 0004-1796-760 1 Gasket 45x60x2
10 0013-0034-300 1 Grooved coupling nut 40
11 0007-3268-820 1 Gasket 10.5x2.5
12 1238-7255-000 1 Flush line
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Fig. 183
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Fig. 184
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Fig. 185
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Fig. 186
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Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
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Fig. 187
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1 8134–2319–100 1 Distributor
2 0004–5982–300 4 Gasket U28.7x35x2
3 8134–2161–040 2 Screw
4 0004–2891–300 6 Gasket U22.7xx30x2
5 8134–2161–050 3 Screw R1/2in
6 0019–0653–400 1 Threaded plug R1inx20
7 0018–5870–610 2 Solenoid valve, compl. 3/4in
8 0018–5947–610 2 Solenoid valve, compl. 1/2in
9 0018–0965–400 3 Double nipple R1/2in
10 0018–0116–400 2 T–Piece DIN 2987 1/2in
11 0018–5936–400 1 Non–return valve
12 0018–4819–600 1 Screwed socket
13 0018–5168–400 2 Transition nipple
14 0001–0299–610 1 Pressure gauge DIN 16063 0–6 bar
15 0001–1196–400 1 Pressure gauge DIN 16063 0–16 bar
16 0019–0559–300 3 Threaded plug R1/2in x15
17 0018–5937–400 2 Screw–on threaded connection 15–R1/2in
18 0007–2521–750 2 Gasket DIN 11851 G 15
19 0018–4573–400 2 Threaded cone connection 15–R1/2in
20 0013–2840–300 2 Grooved coupling nut DIN 11851 F 15
21 0018–0004–300 1 Angle piece DIN 2987 1/2in
22 0018–5286–400 2 Threaded cone connection 25–R3/4in
23 0013–2842–300 2 Grooved coupling nut DIN 11851 F 25
24 8134–2208–150 1 Plate
25 0019–6840–400 4 Hex head screw ISO 4017 M 6x12
26 8134–2059–040 2 Distance piece
27 0026–1382–300 6 Washer DIN 125 6.4
28 0019–6841–300 6 Hex head screw ISO 4017 M 6x16
29 0005–3492–280 1 Terminal box
30 0019–6111–400 4 Allen screw DIN 912 M 6x30
31 0005–0203–630 15 Screw coupling C4PG11
32 0005–0206–630 3 Screw coupling C4PG21
33 8134–2059–030 1 Distance piece
34 8134–2355–090 1 Protective cover
35 0026–0439–300 3 Washer 8.4x25x2
36 0019–6900–300 3 Hex head screw ISO 4017 M 8x12
37 0018–1742–650 1 Water pressure reducer
38 0019–1492–400 1 Threaded plug R1/4
39 0005–4111–010 1 Pressure switch 1–10 bar
40 0005–4111–890 1 Coupler socket
41 8134–2202–030 1 Metering cylinder, compl.
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Fig. 188
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Fig. 189
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Fig. 190
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Accessories
3 0003–0277–800 1 Oil cup 2.7 l
5 0018–384–030 1 Pipe (for fluid clutch)
Lubricants
- 0015–0014–080 5 Lubricating oil CLP 220 2.5 l
– 0015–0050–090 2 Clutch oil DIN 51515 – TDL 32 5l
– 0015–0113–020 4 Lubricating grease KSB 8 40 g
– 0015–0121–000 1 Ball and roller bearing grease 0.85 kg
DIN 51825 – K3k
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Fig. 191
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Fig. 192
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Westfalia Separator AG
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