Westfalia Separator AG

Mechanical Separation
Division

Instruction Manual

No.: 2325-9001-020
Edition: 0806
2 Westfalia Separator AG

©
All rights reserved. No part of this document may be reproduced in any form – by graphic, electronic or me-
chanical means including all types of photocopying or any other means of duplication – without our prior written
consent.
The transmission of originals and reproductions to third parties is prohibited without our prior consent.

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Westfalia Separator AG 3

1 Introduction 7

1.1 About this manual ....................................................................................9

1.2 It is imperative to observe the following instructions to assure safe
operation of the separator......................................................................10
1.3 For your safety.......................................................................................12
1.4 Note on the symbols used in the documentation ..................................13
1.5 Old symbols: ..........................................................................................13

2 Lubrication 17

2.1 Lubricating system.................................................................................18

2.1.1 Oil quality ...............................................................................................19
2.1.2 Oil quantity.............................................................................................19
2.1.3 Oil change..............................................................................................19
2.2 Bowl parts ..............................................................................................20
2.3 Motor bearings.......................................................................................20

3 Motor connection 21

3.1 Three-phase AC motor ..........................................................................22

3.2 Direction of rotation of the bowl .............................................................25
3.3 Bowl speed ............................................................................................25
3.4 Starting time of the bowl ........................................................................26
3.5 Run-down time of the bowl ....................................................................26
3.6 Speed measuring device .......................................................................27
3.7 Electronic vibration monitoring ..............................................................27

4 Bowl 29

4.1 Important hints .......................................................................................30

4.1.1 Special risks of a separator ...................................................................31
4.1.2 Safety precautions for maintenance and repair..................................... 34
4.2 Removing the feed and discharge connections .................................... 39
4.3 Dismantling the bowl..............................................................................42
4.4 Assembling the bowl..............................................................................48
4.4.1 Fitting the centripetal pump ................................................................... 55
4.4.2 Installing the swivel-type actuator..........................................................57
4.5 Assembling the feed and discharge connections .................................. 58
4.6 Replacing the main bowl gasket (bowl top) ...........................................60
4.7 Bowl valves............................................................................................61
4.8 Disk stack compressing device .............................................................63

5 Technical information 65

5.1 Constructional features.......................................................................... 66

5.2 Operating principles of the bowl ............................................................ 68
5.3 Operating principles of the hydraulic system of the bowl ...................... 70
5.3.1 Bowl ejection..........................................................................................71

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5.4 Operating water connection...................................................................72

5.4.1 Solenoid valves......................................................................................73
5.5 Swivel-type actuator for control of the centripetal pump ....................... 73

6 Operation 75

6.1 Before start-up ....................................................................................... 76

6.2 Start-up ..................................................................................................77
6.3 Closing of bowl: .....................................................................................77
6.4 Water run after start-up..........................................................................78
6.4.1 Program control .....................................................................................78
6.4.2 Function diagram of partial ejection.......................................................81
6.4.3 Total ejection .........................................................................................82
6.4.4 Bowl ejection (manual) ..........................................................................82
6.5 Adjusting the separation efficiency ........................................................83
6.5.1 Adjusting the "Fine Tuner" .....................................................................83
6.5.2 Calculation of the "Fine Tuner" diameter...............................................84
6.5.3 Presetting separation.............................................................................84
6.5.4 Adjusting the hydrohermetic feed ..........................................................85
6.5.5 Final adjustment of separating efficiency ..............................................86
6.6 Product mode ........................................................................................86
6.7 Shut-down (Normal Off).........................................................................88
6.8 Shut-down (Emergency-Off) ..................................................................88
6.9 Run-down (overspeed) ..........................................................................89
6.10 After shut-down......................................................................................89
6.11 Prior to a long-term shut-down .............................................................. 89
6.12 Trouble shooting ....................................................................................90

7 Cleaning 95

7.1 Cleaning-in-place...................................................................................96
7.2 Bowl .......................................................................................................99
7.3 Frame...................................................................................................100
7.4 Operating water feeding device...........................................................100
7.5 Cleaning the lube-oil vessel .....................................................................100
7.6 Prior to a long-term shut-down ............................................................101
7.7 Note on cleaning work on hoods .........................................................102
7.8 Note on cleaning work on disks...........................................................102

8 Drive 103

8.1 Drive.....................................................................................................104
8.1.1 Special risks of a separator .................................................................105
8.1.2 Safety precautions for maintenance and repair...................................108
8.2 Fitting and removing the motor............................................................112
8.2.1 Removing the motor ............................................................................112
8.2.2 Installing the motor ..............................................................................113
8.3 Removing spindle assembly, supporting disk......................................114
8.4 Dismantling the spindle assembly .......................................................116
8.5 Assembling the spindle unit .................................................................118
8.6 Replacing the rubber-metal bushes and the rubber cushions.............121
8.7 Installing the spindle assembly............................................................123
8.8 Adjusting the proximity switch .............................................................124

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9 Trouble shooting 125

9.1 Mechanical function .............................................................................126

9.2 Clarifying function ................................................................................130

10 Lubrication and maintenance 135

10.1 Lubrication schedule............................................................................136

10.2 Maintenance schedule.........................................................................137
10.2.1 Guide to ordering spare parts..............................................................138
10.2.2 Use of non-genuine spare parts ..........................................................139

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1 Introduction

1.1 About this manual ....................................................................................9

1.2 It is imperative to observe the following instructions to assure safe
operation of the separator......................................................................10
1.3 For your safety.......................................................................................12
1.4 Note on the symbols used in the documentation ..................................13
1.5 Old symbols: ..........................................................................................13

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Note
Notes
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1.1 About this manual

This manual is part of the documentation supplied with the separator.

Everyone who works with or on this machine must have read and understood
this manual and also the brochure “Safety precautions for separators”.
In order to make available to you the latest safety precautions, they have been
set out in a separate brochure “Safety precautions for separators”.
They reflect the state of the art and are furnished with the separator documenta-
tion.

In the interest of your personal safety and a better understanding of the

machine, please first read the brochure “Safety precautions for separa-
Safety precautions tors” and then this manual.

This booklet must be kept for further use and be available at all times in
the vicinity of the separator for all persons who work with or on the sepa-
rator.
NOTE

The documentation contains important information for all persons who

work with or on the separator. Non-compliance with the instructions in the
documentation can not only result in danger for machines, material and
Caution environment but also endanger persons who work on or in the environ-
ment of the separator.
(danger to life, risk of injury)

At the beginning of this manual, you will find the schematic of the separa-
tor and the nameplate. The nameplate must be filled in by the operator.
Enter the data from the nameplate on the separator. Dangers of later con-
NOTE fusion are thus avoided.

If this machine is used in an explosion-hazarded zone, please first read

the brochure “Separators in explosion-hazarded areas” and then this
manual in the interest of your own safety and for better understanding of
NOTE the machine.

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1.2 It is imperative to observe the following instructions to assure safe

operation of the separator.

1. Assign only adequately trained and competent personnel with operation,

maintenance and repair of the separator.
2. Before every start-up, ensure that all parts are fitted, completely mounted and
that all connections on and around the separator are secure and tight.
3. Never use the separator for a purpose other than the intended and correct
purpose!
4. Never operate the separator at a speed higher than that specified on the
nameplate (rating plate)!
5. Never ignore or acknowledge an alarm without first eliminating the cause!
6. Never start-up or shut-down a partially filled bowl. Danger of imbalance!
7. Never loosen any part before the separator has come to a complete standstill.
Before carrying out maintenance and repair work, switch off the separator, wait
until it has come to standstill and check that all rotating parts have really come
to rest. Then switch off the main switch and lock the machine to prevent it from
accidentally being switched back on.
8. When unusual noises and / or vibrations occur, shut down the separator via
“Emergency Off” and evacuate the room. Never perform an ejection!
9. Never heat the bowl and bowl parts with a naked flame during dismantling!
Welding on the bowl and bowl parts are likewise strictly prohibited.
10. Shut down the separator immediately when damage caused by corrosion or
erosion is detected on the bowl.
11. The hood and solids catchers of steam-sterilizable separators are pressure
vessels. It is prohibited to weld or machine them!
12. Adjust the disk pressure as specified in the documentation. An incorrect disk
pressure can lead to severe imbalance.
13. Have the separator checked by competent, qualified personnel at least once
a year in operating state and at least every 3 years in dismantled state.
14. Do not carry out conversions or modifications to the separator.
15. When working on the separator or with dangerous operating materials, al-
ways wear the necessary protective gear.
16. Operating the separator with hot products leads to hot surfaces of hood, sol-
ids catcher and surrounding piping. Danger of burns!

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17. Always flush the separator after chemical cleaning (CIP).

18. Regularly check the separator, paying particular attention to its nozzles and
ejection system to avoid malfunctions. Where necessary, regularly check con-
centrate nozzles for damage to nozzle stones and soldered joints. Replace
damaged nozzles immediately!
19. Use only genuine spare parts from Westfalia Separator.
20. Ensure that the personnel has access to the documentation and that, in par-
ticular the safety precautions and instructions have been read and understood
before commissioning and working on the separator.

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1.3 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 documentation supplied.

Proceed only in accordance with the documentation supplied.

Operate the separator only in accordance with agreed process

and operating parameters.

Maintain the separator

as described in the documentation supplied.

Carry out safety checks on the separator,

as described in the documentation supplied.

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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1.4 Note on the symbols used in the documentation

Below is an explanation of the meaning of the symbols used in the documenta-

tion.
Special attention must be paid to all passages in the documentation marked
with safety symbols. The operation described after such a symbol must be car-
ried out with utmost care.

This symbol indicates potential danger to persons.

(danger to life, risk of injury)
Caution

This symbol indicates potential risks for machine, material and environ-
ment.
Attention!

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

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

1.5 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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Westfalia Separator
…………….GmbH
D-59302 Oelde ( Germany)

Type Serial-No.

Model

Max. admissible rated bowl speed in min-1

Max. admissible density in kg/dm3 of product

Heavy liquid kg/dm3 Solids kg/dm3

min/max throughput m3/h

min./max. temperature of product in °C

min/max housing pressure range in bar

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2 Lubrication

2.1 Lubricating system.................................................................................18

2.1.1 Oil quality ...............................................................................................19
2.1.2 Oil quantity.............................................................................................19
2.1.3 Oil change..............................................................................................19
2.2 Bowl parts ..............................................................................................20
2.3 Motor bearings.......................................................................................20

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2.1 Lubricating system

Fig. 1

1 External oil lubrication unit

The drive bearings are supplied with oil by the oil circulation lubrication system
(external oil lubrication unit). The oil feed is under pressure, the lube oil return is
under gravity or under pressure, as illustrated above.

For the electrical connection of the external oil lubrication unit, bear in mind that
it has to be switched on when the separator reaches a certain bowl speed dur-
ing start up and that it must be switched off during shut-down.
The specific bowl speeds are listed in the datasheet.
NOTE

For more in-depth information concerning the external oil lubrication unit,
refer to the instruction manual supplied with the oil lubication unit.
Instruction manual

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2.1.1 Oil quality

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

Do NOT use motor vehicle gearbox or engine oils.

NOTE
2.1.2 Oil quantity
Before starting the separator for the
first time fill the oil vessel of the exter-
nal oil lubrication unit with oil until the
oil level reaches the upper mark of the
oil level indicator.
Minimum oil level:
slightly above the lower mark of the oil
level indicator
Maximum oil level:
slightly below the upper mark of the oil
level indicator

Fig. 2

During operation, the oil level in the vessel of the oil lubrication unit must
never be below minimum level; do not fail to re-fill in time (see chapter
“Lubrication and maintenance”, section “Maintenance schedule”).
IMPORTANT

The quantity of oil needed for filling the vessel is indicated in the instruction
manual of the oil lubrication unit.
NOTE

2.1.3 Oil change

The operating hours up to the first oil change and the subsequent oil change
intervals are specified in the “Maintenance Schedule”.

Change the oil at the latest as specified in the “maintenance schedule” even if
the operating hours specified for an oil change have not been reached.
NOTE
Whenever changing the oil, clean the lubricating oil chamber thoroughly with
thin-bodied oil.
Do not use fluffy cleaning rags or cotton waste!
Clean sight glass.

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2.2 Bowl parts

Before assembling the bowl, coat the threads, guide and contact surfaces on
bowl parts such as:
– Bowl bottom,
– sliding piston,
– bowl top,
– lock rings, etc.
with the lubricating pastes or greases specified in the parts list.

Use only lubricants tested by Westfalia Separator for use on separators.

The use of non-genuine parts leads to:
– safety risks,
– less durability of these parts,
– reduced availability of the separator,
NOTE – increased maintenance requirement.

In this case, Westfalia Separator shall assume no liability or warranty.

During assembly, note:

Do not bring gaskets made from the special material EPDM (ethylene-
propylene-diene-caoutchouc) in contact with mineral oils and greases.
Consequence in the event of contact: Swelling of the gaskets
Attention!

EPDM-compatible silicon greases can be used for these gaskets to facilitate

assembly.
The greased surfaces must be free from sand and filings. Otherwise the sur-
faces can become scored.
When cleaning, check the threads, contact and guide surfaces for impact
marks. Impact marks will result in scoring.

2.3 Motor bearings

For lubrication of the motor bearings, refer to the instructions of the

manufacturer (see motor plate).
Instruction manual

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3 Motor connection

3.1 Three-phase AC motor ..........................................................................22

3.2 Direction of rotation of the bowl .............................................................25
3.3 Bowl speed ............................................................................................25
3.4 Starting time of the bowl ........................................................................26
3.5 Run-down time of the bowl ....................................................................26
3.6 Speed measuring device .......................................................................27
3.7 Electronic vibration monitoring ..............................................................27

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3.1 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
– with frequency converter

Belt drive
– with controlled torque motor
– with frequency converter
– with clutch

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

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
Attention! 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:

The separator must never be started without frequency converter.

Attention!

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.

The frequency converter is equipped with a frequency limiter to prevent

the admissible bowl speed from being exceeded.
Additionally, a speed sensor is installed on the separator. The latter
transmits the pulses for bowl speed monitoring to the control system. The
control system switches off the separator when the ceiling speed is ex-
ceeded.
NOTE The separator may be operated only 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.

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Frequency converter operation

The admissible maximum bowl
speed must not be exceeded.

Fig. 3

Before carrying out maintenance or repair work on the motor, bear in

mind that there may still be residual voltage.
CAUTION!

In this connection, refer to the documentation of the frequency converter manu-

facturer and have safety measures implemented by suitable personnel.

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3.2 Direction of rotation of the bowl

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

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 authorized specialist.

3.3 Bowl speed

The bowl speed has been defined to suit the process as a function of the densi-
ties of the centrifugally dry solids and the clarified liquid.
All components have been constructionally rated for this speed (operating
speed) taking into account all safety-relevant factors.
The operating speed (bowl speed) and other important process data are speci-
fied on the separator nameplate. Alterations to the process data may also ne-
cessitate a change in operating speed.

The bowl speed may not be changed by the operator without appropriate
consultation.
The bowl speed stated on the separator nameplate must not be exceeded!

The manufacturer must be contacted before changing process data.

CAUTION! If this instruction is not observed, there is danger to life and limb of the
persons working on the separator by machine parts flying around.

Always check the spindle speed

when drive parts have been re-
placed.
Also pay attention to the direction of
rotation of the spindle and bowl. It
must rotate clockwise (see arrow on
frame). If this is not the case, an
electrician must alter the connection
at the motor.

Fig. 4

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

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3.4 Starting time of the bowl

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

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.

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.
IMPORTANT
Non-observance of this instruction can lead to overheating of the clutch or mo-
tor.

3.5 Run-down time of the bowl

The run-down time of the separator bowl, from switching off to shutdown, is
specified in the data sheet.

The run-down time specified in the data sheet refers to the rated speed (see
separator nameplate) with free run-down and at atmospheric pressure.
NOTE
In addition to mechanical or electric brakes, the run-down time of the separator
can be influenced by various process factors.
The run-down time specified in the data sheet specifies the maximum time
span required until the separator bowl has stopped rotating.

After the run-down time and before working on the separator:

Check that the separator is at a standstill.

Otherwise, there is a danger of injury through rotating bowl parts or dis-

CAUTION!
charging liquids.

Pay attention to the safety precautions relating to “checking standstill”.

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3.6 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.

3.7 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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4 Bowl

4.1 Important hints .......................................................................................30

4.1.1 Special risks of a separator ...................................................................31
4.1.2 Safety precautions for maintenance and repair..................................... 34
4.2 Removing the feed and discharge connections .................................... 39
4.3 Dismantling the bowl..............................................................................42
4.4 Assembling the bowl..............................................................................48
4.4.1 Fitting the centripetal pump ................................................................... 55
4.4.2 Installing the swivel-type actuator..........................................................57
4.5 Assembling the feed and discharge connections .................................. 58
4.6 Replacing the main bowl gasket (bowl top) ...........................................60
4.7 Bowl valves............................................................................................61
4.8 Disk stack compressing device .............................................................63

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4.1 Important hints

The separator bowl rotates at a very high speed.
Hence, forces are produced which can endanger the operating safety of the
machine in case of
– incorrect assembly or
– inadequate cleaning of the bowl.
The instructions for assembly must therefore be followed exactly.
The following points should also be observed:

Before fitting the bowl parts thoroughly clean, grease or lubricate:

Attention!
– Guide and contact surfaces
– Lock ring
When fitting the bowl parts, make sure that the "O" marks on all parts are in
line with each other.
(Only then will the parts fit correctly over arresting pins and guide ribs).
Avoid damage to bowl parts during assembly and dismantling by
– exact positioning.
– avoiding diagonal pull.
– selecting the lower lifting speed of the hoist.

Only use correctly rated, fully functional hoists.

Do not use force to fit or remove parts.
Caution
Before fitting gaskets, check the gaskets and gasket grooves for cleanness
and wear.
After fitting, check that the gaskets
– are not twisted.
– fit evenly into their grooves.
All bowl parts
– must be handled gently
– and placed on a rubber mat or wooden pallet.

In the case of a plant with several separators:

Do not interchange parts of different bowls (danger of imbalance).
Caution
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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4.1.1 Special risks of a separator

The separator is equipped with a high-speed rotating metal bowl which repre-
sents 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.

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!
CAUTION!
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 standstill indication will pro-
vide false information because, for example, the electronics have failed or the
belt or gearbox 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 of gear separators
Optical speed check of the drive motor
Noise check
Vibration check
If you are not sure whether the machine is at a standstill, you must wait for the
run-down time specified in the separator documentation. A subsequent check is
carried out when you are sure that the machine is at a standstill.
Visual speed check by opening the inspection ports on hood and frame
Removing the inspection port in the separator hood enables you to look directly
on to the bowl. In addition, checking is also possible by removing the gearbox
cover or opening the port in the frame.

Only when you are convinced that the separator is at a standstill can the
following checks be carried out for additional security.
NOTE

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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. 5

Revolution visual check on ma-

chines with gearbox.

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. 6

Revolution visual check on ma-

chines with direct 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. 7

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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.
NOTE

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

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

CAUTION! 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.

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

CAUTION! Danger of frostbite!

Depending on type and installation site, hazards in the form of noise

emission from the separator may occur. Therefore, always wear protective
gear in accordance with the national regulations.

CAUTION!
Danger of hearing damage!

During all maintenance and repair work on the separator, the fittings and
pipelines, there is the risk of injury due to spurting liquids, e.g. hot or
caustic liquids can spurt out under pressure.

CAUTION! Danger of causticization of skin and eyes!

2325-9001-020 / 0806
34 Westfalia Separator AG

4.1.2 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. Reduce the
maintenance intervals to adapt 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 main-
tenance schedule to assure safe and
efficient operation.

Fig. 8

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. 9

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

2325-9001-020 / 0806
Westfalia Separator AG 35

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. 10

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.

Do not heat bowl parts with a

naked flame to facilitate disman-
tling work.
Structural changes in the material of
the bowl parts which affect the operat-
ing safety of the machine may result!

Do not weld bowl parts.

Fig. 11






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

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36 Westfalia Separator AG

Place the dismantled separator

parts on suitable surfaces (rubber,
wood etc.).
Take appropriate steps to prevent
machine parts from overturning and
rolling away.

Fig. 12

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. 13

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 operated

when locking devices and marks on
the bowl parts are damaged.

Fig. 14

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Westfalia Separator AG 37

After fitting certain new 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 specialist workshops
authorized by Westfalia Separator!

If in doubt, consult the service de-

partment of Westfalia Separator.

Fig. 15

Unqualified balancing can lead to dangerous operating states and to de-

struction of the separator with danger to life and limb of the personnel.
CAUTION!

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

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38 Westfalia Separator AG

Lock ring

Gasket
Centripetal pump
Chamber cover

Separating disk
Centripetal pump
Chamber cover
Gasket Gasket
Upper centripe-
tal pump Distance sleeve
Centripetal pump
Gasket
Chamber cover

Gasket
Disk
Gasket
Centripetal pump
Chamber cover

Gasket

Gasket

Distance sleeve

Gasket

Distributor

Sleeve Lower distributor

Feed tube
Gasket
Spindle screw

Sliding piston Gasket

Gasket
* Lock ring

Gasket
Gasket
* Bowl top

Bowl bottom
Gasket

Gasket

Fig. 16

*) Attention: After replacing this part, the complete bowl must be re-balanced!

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Westfalia Separator AG 39

4.2 Removing the feed and discharge connections

Switch off and lock the main switch.

Caution!
To prevent accidents, do NOT loosen any part before the bowl has
stopped completely!
Caution
Standstill of the bowl is indicated by
– LED "bowl standstill" or
– the speed indicator in the control unit or in the motor control or
– revolution indicator or
– gear standstill, visible through the sight glass on the frame.
Replace worn gaskets immediately.
For tools, see separate order-specific parts list.
Stop compressed-air supply.
Disconnect electrical connection 1
and compressed-air supply 2.
Note:
This has to be done before remov-
ing the guards - danger of crush-
ing!

Caution

Fig. 17

Disconnect the following lines:

– Cooling lines of the hood cooling,
– flush water line,
– supply line to hood flushing.
Disconnect the feed and discharge
lines.
Cut off the electrical connection to
the contact pressure gauge and
sight glass illumination.
Unscrew vent line 2.
Unscrew connection piece 1.
Lift off the connection housing.

Fig. 18

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40 Westfalia Separator AG

Unscrew hex head screws 3.

Remove protecting-case halves 1
and 2.

Fig. 19

Remove toothed segment 3.

Fig. 20

Unscrew hexagon nuts 5.

Thread two eye bolts 1 into the ta-
pholes.
Lift off ring 2 together with swivel-
type actuator. For the transport, use
lifting device, if required (correct ap-
plication is shown on (Fig. 23 ).

Fig. 21

Screw two ring nuts opposite each

other onto the studs of the hood.

Fig. 22

2325-9001-020 / 0806
Westfalia Separator AG 41

Unscrew the screws for fastening

the hood.
Shorten the chains of the lifting de-
vice.
Hang the shortened lifting device
into the lifting-eye nuts and lift off
the hood.

Fig. 23

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42 Westfalia Separator AG

4.3 Dismantling the bowl

Unscrew centripetal pump chamber
lock ring by lightly hammering
against the handle of the annular
wrench (left-hand thread).
Lift off the centripetal pump lock
ring.

Fig. 24

Lift off centripetal pump chamber

cover using lifting tongs 1.

Fig. 25

Remove cover 1.

Fig. 26

Pull off the distance sleeve 1 with

upper centripetal pump.

Fig. 27

2325-9001-020 / 0806
Westfalia Separator AG 43

Remove upper centripetal pump 1.

Fig. 28

Lift off centripetal pump chamber

cover 1.

Fig. 29

Pull off lower centripetal pump 1.

Fig. 30

Force off centripetal pump chamber

cover 1 by screwing in hex head
screws 2.
Lift off centripetal pump chamber
cover 1.
Unscrew hex head screws 2.
Pull off disk 3.

Fig. 31

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44 Westfalia Separator AG

Lift out feed tube 1 with lower dis-

tributor 2.

Fig. 32

Unscrew spindle screw with the

wrench (left-hand thread).

Fig. 33

2325-9001-020 / 0806
Westfalia Separator AG 45

Mounting the compressing device:

Screw threaded rod 1 as far as it will
go into the bowl bottom (left-hand
thread).
Insert hydraulic part 3 into the cen-
tering recess of the disc 4.
Screw on threaded ring 2 until its
upper edge is flush with end thread
of bolt 1 (left-hand thread).

Fig. 34

To prevent damage to threads:

Screw in threaded bolt completely.

Attention!
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.
In this case:
Bring piston and cylinder into initial position:
– Loosen pressure relief screw 5 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.
Close pressure relief screw 5.
Compress the disk stack to facilitate
loosening of the bowl lock ring.
Compression: See data sheet.
Loosen the bowl lock ring by ham-
mering against the handle of the
wrench with a mallet (left-hand
thread).

Fig. 35

If the lock ring is jammed tight, loosening can be considerably facilitated by

heating the upper part of the bowl bottom with steam or hot water. Do not use
any other sources of heat, e.g. blow torch or welding torch.

2325-9001-020 / 0806
46 Westfalia Separator AG

Dismantling the compressing de-

vice:
Move pump lever of compressing
device down as far as it will go to
prevent it from jumping back.
Loosen pressure relief screw 5.
Unscrew threaded ring 2 (left-hand
thread).
Remove hydraulic unit 3 and disk 4.
Unscrew bolt 1 (left-hand thread).

Fig. 36

Unscrew bowl lock ring completely

and lift it out using device 1 and eye
bolt 2.

Fig. 37

Insert disk 1 in the distributor neck.

Screw lifting device 2 onto the bowl
top.
Force off the bowl top by turning the
spindle clockwise and lift it out.
Take disk 1 out of the distributor
neck.

Fig. 38

Screw lifting device 1 into the dis-

tributor.
Force off the distributor together
with the disc stack by turning jack-
screw clockwise.
Lift out distributor with disk stack.

Fig. 39

2325-9001-020 / 0806
Westfalia Separator AG 47

Place pressure piece A of the lifting

device (sliding piston) on the hub of
the bowl bottom.
Grease outer surface of the pres-
sure piece.

Fig. 40

Screw lifting device 1 onto the slid-

ing piston (left-hand thread)..
Force sliding piston off the bowl
bottom by turning threaded spindle
2 clockwise.
Lift off sliding piston.
Make sure that the sealing lip of the
sliding piston does not get dam-
aged.

Fig. 41

Pressing off the bowl bottom:

Screw pressure piece 7 into
threaded bolt 4.
Screw eye bolt 3 into the upper bolt
end 4.
Screw the entire device into the
thread of the bowl bottom as far as it
will go (left-hand thread).
Force the bowl bottom off the spin-
dle cone using the wrench which is
placed over the hexagon at the up-
per threaded bolt end.
Fig. 42

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48 Westfalia Separator AG

4.4 Assembling the bowl

Handle bowl parts with care.
Assemble the bowl on a rubber mat or wooden pallet.
Grease threads and guide surfaces of the bowl parts.
Replace worn gaskets.
For tools, see order-specific parts list.
Transport the bowl bottom using the
threaded spindle.

Fig. 43

Thoroughly clean gasket groove in

the sliding piston and apply a thin
film of grease.
Insert gasket into the groove of the
sliding piston.

Fig. 44

Insert the gaskets in the grooves in

the bowl bottom.

Fig. 45

2325-9001-020 / 0806
Westfalia Separator AG 49

Place pressure piece 1 of lifting

device for sliding piston onto hub of
bowl bottom.

Fig. 46

Grease guide surfaces of the sliding

piston and bowl bottom.
Insert the sliding piston using the
lifting device so that the "O" marks
are perfectly aligned.
Lower the sliding piston slowly by
turning the jackscrew counter-
clockwise until the arresting pins of
the bowl bottom catch into the holes
of the sliding piston. If necessary,
jolt the piston until it snaps into posi-
tion.
Fig. 47

Make sure that the sealing lip B of the sliding piston does not get dam-
aged.
Attention!
After inserting the sliding piston take out pressure piece A.
Turn distributor through 180o.
Install lower distributor 1 so that the
cams in the lower distributor and
distributor
– are aligned,
Secure lower distributor 1 against
falling out by screwing in cylindrical
pin 2.
Turn around distributor again.

Fig. 48

2325-9001-020 / 0806
50 Westfalia Separator AG

Stack the disks onto the neck of the

distributor in numerical order, be-
ginning with number 1.

Fig. 49

Grease contact surfaces.

Install distributor together with disks
in the bowl bottom.
The "O" marks on the bowl bottom
and distributor must be aligned; the
grooves in the bowl bottom will then
catch into the locking devices of the
distributor.

Fig. 50

Install separating disk with inserted

gaskets.
The "O" marks on the separating
disk and bowl bottom must be
aligned.

Fig. 51

Clean and grease guide surfaces

and threads of the bowl bottom.
Insert disc 1 of the lifting device
(bowl top) into the distributor neck
as a support for the lifting device.

Fig. 52

2325-9001-020 / 0806
Westfalia Separator AG 51

Insert the gaskets in the grooves of

the bowl top.
If the main bowl gasket has to be
replaced, see chapter “Replacing
main gasket”.
Clean and grease guide surfaces of
the bowl top.

Fig. 53

Place bowl top on bowl bottom with

the aid of the lifting device A. Slowly
lower the bowl top by turning the
threaded spindle B counterclock-
wise.
Make sure that the arresting piece
of the bowl bottom catches into the
groove of the bowl top.
The "O" marks on both parts must
be aligned.
Unscrew disk from the distributor
neck.
Fig. 54

Check and grease threads as well

as contact and guide surfaces (see
arrows).

Fig. 55

Place bowl lock ring on the bowl

bottom using lifting device 1 and eye
bolt 2.
First screw in the bowl lock ring
using the pin spanner by hand (left-
hand thread).

Fig. 56

2325-9001-020 / 0806
52 Westfalia Separator AG

Take disk 1 of the lifting device out

of the distributor neck.

Fig. 57

Mounting the compressing device:

Place disc 4 on the bowl top.
Screw bolt 1 as far as it will go into
the bowl bottom (left-hand thread).
Insert hydraulic part 3 into the cen-
tering recess of the disc.
Screw on threaded ring 2 until its
upper edge is flush with end thread
of bolt 1 (left-hand thread).

Fig. 58

To prevent damage to threads:

Screw in threaded bolt completely.

Screw on threaded ring down to thread end.
Attention!
If the threaded ring cannot be screwed down completely, then the piston and the
cylinder of the compressing device are too far apart.
In this case:
Bring piston and cylinder into initial position:
– Loosen pressure relief screw 5 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.
Close pressure relief screw 5.
Compressing the disk stack:
Pressure must be gradually applied to
the disk stack until the max. disk com-
pression is attained, see data sheet.
Each pressure increase should be
approx. 50 bar.
After each pressure increase, tighten
bowl lock ring further.
When the max. disk compression of
(see data sheet) 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.
Fig. 59

2325-9001-020 / 0806
Westfalia Separator AG 53

If the maximum pressure is not attained and grease flows out of the stroke limit-
ing hole, bolt 1 has not been screwed far enough into the bowl bottom.
The compressing device is not ready for use again until bolt 1 and threaded ring
2 have been brought back into the position as described above.
When compressing the disc stack, make sure that the arresting piece of the
bowl bottom snaps into the groove of the bowl top and that the bowl top does
not become twisted when lowered.
Hit wrench handle with the mallet to
obtain "O" mark alignment (left-
hand thread).

Fig. 60

If the lock ring can be tightened by hand up to the “O” mark at maximum disk
compression, add a spare disk or compensating disk.
In the case of newly fitted disk stacks, the pressure in the disk stack can
slacken due to settling of the disks. For this reason, check the pressure in the
disk stack several times using the procedure described above.
At least once a month in the first 3 months.
Dismantling the compressing de-
vice:
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 5.
Unscrew threaded ring 2 (left-hand
thread).
Remove hydraulic unit 3 and disk 4.

Fig. 61

Unscrew the hex head screws of the

pin spanner and remove it.
Unscrew the eye bolt.
Screw hex head screws with fitted
gasket into the lock ring.

Fig. 62

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54 Westfalia Separator AG

Before placing the bowl on the spin-

dle, oil the upper part of the spindle
(thread and cone).
Clean and dry the conical part of
the spindle and the inside of the
bowl hub with a cloth to ensure
proper fitting.

Fig. 63

Screw the eye bolt onto the

threaded rod.

Fig. 64

Lower the bowl on the spindle.

Dismantle the device.

Fig. 65

Screw spindle screw (with inserted

gasket) firmly into the spindle (left-
hand thread).

Fig. 66

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Westfalia Separator AG 55

4.4.1 Fitting the centripetal pump

Introduce feed tube 1 with gasket 2
into the bowl.
Fit lower distributor 3 with inserted
gasket 4.
Pay attention to correct positioning!
Put spacer 5 and gasket 6 on the
feed tube.
Place on centripetal pump chamber
cover 7 with inserted gasket 8. Pay
attention to correct positioning!
Install lower centripetal pump 9 with
gasket 10.
Mount centripetal pump chamber
cover 11 with gasket 12.
Mount distance sleeve 13 with gas-
ket 14.
Install upper centripetal pump 15
with gasket 16.

Fig. 67

Pay attention to correct position-

ing; check assembly of centripe-
tal pump components.

Fig. 68

Clean and grease threads on bowl

top and in the lock ring.
Install upper centripetal pump 1 with
fitted gaskets and tilt towards the
bowl centre.

Fig. 69

2325-9001-020 / 0806
56 Westfalia Separator AG

Mount centripetal pump chamber

cover pos. 1.

Fig. 70

Place on centripetal pump chamber

cover with inserted gasket.
Pay attention to correct positioning!
The "O" marks must be aligned.

Fig. 71

Clean and grease threads on bowl

top and in the lock ring.
Screw on the lock ring by hand and
tighten it by hammering against the
handle of the annular wrench (left-
hand thread).

Fig. 72

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Westfalia Separator AG 57

4.4.2 Installing the swivel-type actuator

Fig. 73

Exploded view of the swivel-type actuator

The swivel-type actuator need not be dismantled when the bowl is to be re-
moved. If, however, the swivel-type actuator has to be dismantled in order to re-
place a defective component, the bowl has to be removed and reinstalled as
shown in Fig. Fig. 73.
Also keep in mind the following points:
The pointer indicating the angle of setting must be on "0".
Place on the drive pinion as shown in Fig. Fig. 73.

2325-9001-020 / 0806
58 Westfalia Separator AG

4.5 Assembling the feed and discharge connections

Screw two ring nuts opposite each
other onto the studs of the hood.

Fig. 74

Shorten the chains of the lifting de-

vice.
The chain link must be put cross-
wise on hook A (see adjacent small
figure)!
Hang the shortened lifting device
into the lifting-eye nuts and place
the hood on the solids catcher.
Bolt hood and solids catcher to-
gether using hex head screws.

Fig. 75

Thread two eye bolts 1 into ring 2.

Insert gasket 3.
Place on ring 2 together with the
swivel-type actuator.
Fasten ring 2 by means of hex head
screws 5 with installed lock washers
4.

Fig. 76

The pointer must be on "0" (see

arrow).
Place toothed segment 3 on cen-
tripetal pump 2 (watch for "O" mark
alignment).
Insert toothed segment 3 so that the
marks of the teeth of segment 3 and
of the drive pinion are placed oppo-
site to each other (see arrows).
For this purpose, the centripetal
pump has to be turned while the
toothed segment is held in a slightly
Fig. 77 inclined position.

2325-9001-020 / 0806
Westfalia Separator AG 59

Place on protecting-case halves 1

and 2, and fasten them with hex
head screws 3.

Fig. 78

Install the discharge.

Connect the feed and discharge
lines.
Connect vent line 2.
Screw tight connection piece 1 with
inserted gasket.

Fig. 79

Connect the following lines:

– Cooling lines of the hood cooling,
– flush water line,
– supply line to hood flushing.
Make electrical connections to the contact pressure gauge.
Fit sight glass illumination.
Connect current supply 1 and com-
pressed-air supply 2.
Note:
The protecting cases must be in
place - danger of crushing!

Caution

Fig. 80

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60 Westfalia Separator AG

4.6 Replacing the main bowl gasket (bowl top)

Removal
Screw wooden screw 1 into the
gasket.
Lever out the gasket with screw-
driver 2.

Fig. 81

Fitting
Insert the gasket in the cleaned
groove of the bowl top (with the nar-
row side towards the bowl top).
Drive the gasket evenly into the
groove.
If the diameter of the gasket is too
small, place it in a water bath of 70 -
80 oC for about 5 minutes. The gas-
ket will then assume its original di-
mensions.

Fig. 82

Drive the gasket into the groove so

far that the sealing area of the gas-
ket does not protrude above surface
"A" of the bowl top by more than 1
mm.

Fig. 83

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Westfalia Separator AG 61

4.7 Bowl valves

Remove and clean the bowl valves once a month.

Screw wrench 1 (bowl valve) into

the bowl valve.

Fig. 84

Push sleeve a of the wrench to-

gether with the pins into the holes of
the bowl valve.
Tighten collar nut b.
Unscrew bowl valve from bowl bot-
tom using socket wrench 1.

Fig. 85

If the valve piston 2 remains stuck in

the bowl bottom while pulling out the
valve:
Screw wrench 3 (for valve piston)
into the valve piston.
Pull the valve piston out of the bowl
bottom by means of the wrench.

Fig. 86

At the same time, check the gaskets and replace them if necessary.

2325-9001-020 / 0806
62 Westfalia Separator AG

Use the tools stated in the parts list to fit the gaskets.

Stretch the gasket 3 over the ex-

panding mandrel 4 and fit in piston
valve 1.

Fig. 87

Stretch gaskets 3 and 5 over ex-

panding mandrel 2 and 4 and fit in
piston 1.

Fig. 88

For installation proceed in opposite order of removal.

Pay special attention to the following:
Moisten gaskets.
Grease threads.
Screw in valve as far as it will go, but not too tightly .
The front face of the valve housing must be flush with the outer wall of the bowl
bottom.

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Westfalia Separator AG 63

4.8 Disk stack compressing device

1 Filling device
2 Clamping piece
3 Grease cartridge
4 Pumpenkopf
5 Non-return valve
6 Pressure chamber
7 Hydraulic cylinder
8 Piston
9 Bolt
10 Disc
11 Hydraulic part
12 Threaded ring
13 Stroke-limiting hole
14 Venting screw
15 Pressure gauge (0-600 bar)
16 Pressure relief screw

Fig. 89

Operating principles
The pump presses grease at a high pressure into pressure chamber 6.
The increase in pressure in the pressure chamber displaces piston 8 in relation
to hydraulic cylinder 7.
The hydraulic part 11 (piston, hydraulic cylinder) is bolted securely to the bowl
bottom by means of bolt 9 and threaded ring 12.
When the pressure increases in pressure chamber 6, piston 8 is forced down-
wards.
The force produced is transferred via disk 10 on to the bowl top. The disc stack
is compressed.

Required compression: see datasheet

maximum pressure: see datasheet

Pump
The pump produces a pressure of max. 400 bar. It consists of:
pump head
grease cartridge
filling device
non-return valve

2325-9001-020 / 0806
64 Westfalia Separator AG

Filling the grease cartridge

Cartridge filling: 450 g special grease K2R
The grease cartridge of the compressing device is filled with special grease be-
fore shipment.
Actuate clamp piece 2 and pull the filling device 1 upwards.
Unscrew grease cartridge 3 from pump head 4.
Fill in grease, approx. 450 g.
Screw grease cartridge 3 into pump head 4.
Actuate clamp piece 2 and push filling device 1 into grease cartridge 3.
Fill the grease cartridge only with WS special grease K2R.
If there is no build-up of pressure, the following must be checked:
Is the pressure relief screw 16 screwed in tightly?
Is there enough K2R grease in the grease cartridge?
Has piston 8 travelled too far out of hydraulic cylinder 7?
If yes:
Unscrew pressure relief screw 16 a
little way.
Press piston 8 back into hydraulic
cylinder 7. This must be done in the
absence of pump pressure.
Re-tighten pressure relief screw 16.

7 Hydraulic cylinder
8 Annular piston
9 Bolt
16 Pressure relief screw

Fig. 90

If grease oozes out through the stroke limiting hole 13, bolt 9 and threaded
ring 12 have not been screwed into their final position, and the stroke is too
long.

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Westfalia Separator AG 65

5 Technical information

5.1 Constructional features.......................................................................... 66

5.2 Operating principles of the bowl ............................................................ 68
5.3 Operating principles of the hydraulic system of the bowl ...................... 70
5.3.1 Bowl ejection..........................................................................................71
5.4 Operating water connection...................................................................72
5.4.1 Solenoid valves......................................................................................73
5.5 Swivel-type actuator for control of the centripetal pump ....................... 73

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66 Westfalia Separator AG

5.1 Constructional features

Fig. 91

Self-cleaning bowl:
– The bowl can be emptied during operation by means of a hydraulically ac-
tuated sliding piston 17.
Closed feed and discharge of the product phases:
– The product is fed into the machine through a closed line system.
– For product observation illuminated sight glasses are fitted in feed 3, clean
oil discharge 4 and heavy phase discharge 2.
– A pressure switch monitors the discharge pressure of the light phase.
– Soap or gums are discharged through a closed discharge pipe.
"Fine Tuner":
– With the aid of "Fine Tuner" 6 the separating zone in the disk stack can be
altered while the separator is running. By this means, the separator can be
optimally adapted to changes in the product (e.g. different oil types).
During start-up and bowl ejections the separating zone can temporarily be
displaced to the centre to prevent oil carry-over at the separating disk outer
diameter.
Hydrohermetic feed:
– The product is fed into the bowl gently and with slight overpressure through
hydrohermetic feed 10.
"Steam seal":
– A hydrohermetic seal 9 prevents clouding of the oil due to vapours from the
inlet chamber.

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Westfalia Separator AG 67

"Bowl Flush":
– Liquid can be fed into the outer solids space via a separate channel 5.
By this means, surplus lye or acid can be flushed out or a high-viscous
phase can be diluted and conveyed more easily out of the bowl.
–
The separator is also equipped with a
direct drive (without belt and gear)
three-phase AC motor for FC operation
external lubricating oil unit for oil circulation lubrication

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5.2 Operating principles of the bowl

Fig. 92

1 Control unit 14 Flush water channel (”Bowl Flush”)

2 Heavy phase discharge 15 Solids holding space
3 Feed 16 Solids ejection ports
4 Discharge (light phase) 17 Sliding piston
5 Flush water channel (”Bowl Flush”) 18 Closing chamber
6 Centripetal pump – heavy compo- 19 Piston valve
nent (”Fine Tuner”)
7 Centripetal pump – light component 20 Opening water
8 Distributor 21 Closing–water
9 ”Steam seal” 22 Metering piston
10 Hydrohermetic feed 23 Control air
11 Disk stack 24 Filling water / opening–water
12 Rising channels 25 Cooling medium
13 Separating disk channels

The bowl is used to separate mixtures that consist of

– a liquid (oil) and
– pasty substances (soapstock or gums) with simultaneous removal of the
solids contained in the mixture.
The product
flows through feed 3 into the bowl,
and is separated in disk stack 11.
The disk stack consists of a large number of conical disks placed on top of one
another.
Due to the narrow interspaces between these disks
the liquid is split up into thin layers and
the settling path is minimized.

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The light component

flows to the bowl center,
then flows to the centripetal pump chamber,
is discharged under pressure by centripetal pump 7,
and led off through discharge pipe 4.
The heavy component
flows out of the disk stack to the periphery,
flows over the separating disk to the centripetal pump chamber,
is discharged under pressure by centripetal pump 6,
and is led off under gravity through a discharge pipe.
The solids particles
are flung against the underside of the disk above,
slide outwards into the solids holding space 15,
are periodically discharged through solids ejection ports 16.
Solids ejection is initiated by control unit 1.

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5.3 Operating principles of the hydraulic system of the bowl

Closing the bowl
When the bowl has reached its rated
speed, solenoid valve 12 for closing
water is opened briefly several times.
The closing water flows into the clos-
ing chamber 3 beneath the sliding
piston 4.
Due to the rotation, pressure builds up
in the closing chamber. This pressure
creates force in axial direction which
presses the sliding piston against gas-
ket 9 of bowl top, thus closing the sol-
ids holding space 11 during the sepa-
ration process.
Closing chamber 3 is sealed by valve
piston 7 which is pressed through
centrifugal force against gasket 8 and
thus closes discharge hole 10.
In order to compensate for closing
water losses, closing water and filling
water are supplied every 5 mins for
1sec via an interval switching ar-
rangement.

Fig. 93

Opening the bowl (ejection)

To empty the solids holding space opening
water 13 is added which flows from injec-
tion chamber 2 through feed hole 5 to
piston valve 6. Due to hydraulic opening of
the valve the water discharges from the
closing chamber through hole 10:
for partial ejection the closing chamber
empties partially,
for total ejection it empties completely.
As the liquid level recedes the closing
pressure acting on the underside of the
sliding piston decreases quickly. As soon
as it is smaller than the opening pressure
acting on the upper side of the piston, the
sliding piston is pressed downwards, thus
opening the ejection ports in the bowl
bottom: the solids are then ejected instan-
taneously through the ejection ports 14 of
the bowl.
Once the ejection has taken place,
– opening-water valve 13 closes
– closing-water valve 12 opens.
Piston valve 6 re-seals discharge hole
10 and the closing chamber fills with
water again. The sliding piston is
forced back into closed position.

Fig. 94

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5.3.1 Bowl ejection

When to empty the bowl?
The intervals at which solids ejections have to take place depend on the solids
content and on the nature of the process liquid. If possible, the solids holding
space should not be filled to the brim.
As soon as the separation or separation efficiency starts to deteriorate, either a
total ejection or partial ejection must be carried out.
During a total ejection the whole bowl contents are ejected, during a partial ejec-
tion only part of the bowl contents.
Whether partial or total ejections or a combination of both are carried out de-
pends on the mechanical behaviour of the solids during bowl ejection.
Partial ejection
Partial ejection is a term used to denote partial emptying of the solids holding
space of the bowl.
The product feed is not interrupted during partial ejections.
The amount to be ejected can be adjusted externally during operation between
5 - 30 l.
For partial ejection, opening water is fed to the hydraulic system via the meter-
ing device E.
The amount of solids to be ejected is primarily determined by the opening water
volume.
The opening water volume is adjusted on the metering device.
Adjusting the amount to be ejected
Adjusting by means of the adjusting
screw of the metering device.
Reduce ejection volume.
Turn adjusting screw clockwise
Increase ejection volume:
Turn adjusting screw anti-clockwise

Fig. 95

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5.4 Operating water connection

The operating water connection is equipped with solenoid valves, pressure re-
ducer and pressure switch.
The function of the pressure switch is to monitor the operating water pressure.
If the pressure drops below a preset minimum value, an alarm is given and the
separation program interrupted.

Operating water connection: 1¼ in

Operating-water pressure: Pmin. = 2,0 bar
(with open closing water valve) Pmax. = 2,5 bar

Operating water capacity: = min. 4000 l/h

Air pressure for metering unit: Pmin. = 4,0 bar
Pmax. = 6,0 bar

Note:
Prior to a partial ejection there is a
brief water pressure increase in the
operating water connection. This can
be read off on pressure gauge 2.
Adjust the air pressure for the meter-
ing unit so that the heightened water
pressure is lower than the maximum
pressure marked on solenoid valve 1.

Fig. 96

If the setting is wrong no partial ejection is possible.

Standard operating water values:

D Suspended matter in operating water: max 10 mg/l
D Particle size: max. 50 µm
D Hard- 12 odH separating temperature up to 55oC
ness:
6 odH at separating temperatures above 55 oC
To convert the hardness values stated use the follow-
ing equation:

1odH = 1.79ofH = 1.25oeH = 17.9 ppm CaCO3

D Chloride content: 100 mg/l
D pH value: 6.5 – 7.5

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5.4.1 Solenoid valves

The solenoid valves incorporated in the operating-water system are 2/2-way
straight-way diaphragm valves with internal piloting.
The solenoid coil is entirely embedded in epoxy resin which ensures protection
against moisture, good dissipation of heat, and perfect electrical insulation.
The valves are fully tropicalized.
Maintanance
The solenoid valves do not require special maintenance.
Electrical faults
Shut off main valve for operating-water.

Fault Cause Remedies

Valve does not func- Control unit defective. Contact servicing
tion. staff.
Connecting terminal Tighten screw of con-
on terminal strip is necting terminal.
loose.
Coupler socket loose Tighten coupler
or leaks. socket and replace
gasket, if necessary.
Solenoid coil defec- Replace complete
tive. solenoid head.

5.5 Swivel-type actuator for control of the centripetal pump

The swivel-type actuator is controlled by means of an electric unit signal. As au-
xiliary anergy, instrument air (dry and free of dust) is required.

Air pressure: Pmin = 4bar

Pmax = 6 bar
Flow rate: approx. 93 Nl/min

! The centripetal–pump diameters required

a) for operation (" large diameter) and
b) for start–up / partial ejection (" small diameter) are entered on
the control unit.
The values entered are transformed to a certain electric signal.
This signal causes the centripetal pump to enter into the desired
position. The actual position can be read from the separator.

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Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note

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6 Operation

6.1 Before start-up ....................................................................................... 76

6.2 Start-up ..................................................................................................77
6.3 Closing of bowl: .....................................................................................77
6.4 Water run after start-up..........................................................................78
6.4.1 Program control .....................................................................................78
6.4.2 Function diagram of partial ejection.......................................................81
6.4.3 Total ejection .........................................................................................82
6.4.4 Bowl ejection (manual) ..........................................................................82
6.5 Adjusting the separation efficiency ........................................................83
6.5.1 Adjusting the "Fine Tuner" .....................................................................83
6.5.2 Calculation of the "Fine Tuner" diameter...............................................84
6.5.3 Presetting separation.............................................................................84
6.5.4 Adjusting the hydrohermetic feed ..........................................................85
6.5.5 Final adjustment of separating efficiency ..............................................86
6.6 Product mode ........................................................................................86
6.7 Shut-down (Normal Off).........................................................................88
6.8 Shut-down (Emergency-Off) ..................................................................88
6.9 Run-down (overspeed) ..........................................................................89
6.10 After shut-down......................................................................................89
6.11 Prior to a long-term shut-down .............................................................. 89
6.12 Trouble shooting ....................................................................................90

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6.1 Before start-up

Note:
– Instructions in the brochures:
“Separators in explosion-hazarded zones”,
“Machine controls for separators”,
“Safety precautions on the separator”.
– Process dependent modifications reserved – refer to the project-related
documentation.
– Only feed product which conforms to the specifications on the nameplate.
Check that
– the machine has been correctly assembled,
– the bowl is fitted,
– the bowl lock rings have been tightened securely,
– the screws for fastening the hood and the feed and discharge housing are
tightened securely,
– the centripetal pump with connection piece is tight,
– the frame drains are open,
– enough oil has been filled in (see manual of external lubricating oil unit),
Open shut-off valves in supply lines for
– operating water,
– cooling water
– hood flush water,
– control air
Press "Release" button.
Check that
– the specified pressures are indicated on the respective pressure gauges for
– operating water,
– braking water
– control air
Fill the siphon (when cooling medium does not discharge via siphon).

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6.2 Start-up
Press the "Separator ON" button.
– Signal lamp "Start" lights up.
LED "Bowl standstill" on the mimic display of control unit goes out as soon as
the drive rotates.
Together with the main motor the external fan is switched on automatically.
The bowl speed can be read off from the speed indicator.
The power consumption of the main drive motor is indicated by the ammeter.
After approx. 4 minutes start-up and reaching half the bowl speed, switch-
over to run-up takes place speed-dependently.
– Signal lamp "Run-up" lights up.
After a further 8 minutes, switch-over to operation takes place speed-
dependently.
– Signal lamp "Operation" lights up.
The operating speed is reached (see separator nameplate).
The ammeter indicates the no-load current of the machine.
The lubricating oil unit is started at a certain bowl speed (see data sheet).
– The oil circulation is monitored by a pressure switch. If the pressure in the
oil line drops below the minimum value, the fault is signalled. The separator
is switched off after a pre-set delay time.
If severe vibrations occur during start-up, stop the separator immediately via
"Emergency-Off" and check when the bowl is at rest whether the bowl is cor-
rectly assembled and thoroughly cleaned.
Separators equipped with a vibration monitoring system are continuously
monitored for unduly high mechanical vibrations and automatically stopped
upon exceeding the limit value stage 2.

Never initiate a total ejection when the separator is vibrating severely.

Strong unbalance of the separator may result.
Damage of dame to assets and persons due to machines flying round.
Attention!

6.3 Closing of bowl:

After having switched over from acceleration to operation, two total ejections are
carried out automatically in order to close the bowl. Unless this program has
been activated, the two total ejections have to be initiated manually by pressing
the corresponding function key.
To prevent water losses, closing water is injected every 5 minutes for one sec-
ond.
All program time settings are variable.
Closing-water injection is indicated by an LED in the separator symbol on the
timing unit.

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6.4 Water run after start-up

Check that
– metering device on the operating water connection is correctly adjusted.
– program times are set on the control unit to suit the operating conditions.
Feed separator with water.
Check that the bowl is watertight.
– Bowl leakage is indicated by a higher reading on the ammeter.
– When bowl leakage is detected,
terminate the water run,
press "total ejection" button.
– Refill the bowl with water and check that it does not leak.
– If the bowl cannot be made watertight after several attempts.
Press "total ejection" button.
Warm up the bowl for max. 15 minutes without water. The polyamide ring
adapts to the sealing surface of the sliding piston.
– Refill the bowl with water and check that it does not leak.
– If bowl leakage persists,
shut down the separator via "Normal Off".
Dismantle and check the bowl after standstill (polyamide gasket, gaskets of
bowl hydraulic system etc.).
Ejection progress is shown by LEDs in the valve symbols.

6.4.1 Program control

A PLC unit is used for automatic program control of the separator.
Consult the control unit manual for further information.

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Function of the metering device

The metering device E is filled with
water via filling valve A after every
ejection.
For partial ejection chamber F is sup-
plied with compressed air.
Through actuating the opening water
valve D the adjusted water volume is
displaced by air pressure and fed to
the hydraulic system of the bowl.

A Solenoid valve filling water

B Solenoid valve closing water
C Solenoid valve hood flush water
D Solenoid valve opening water
E Metering device
F Air chamber
P Solenoid valve cooling water

Fig. 97

Program sequence
Refer also to section 6.4.2.
After the program time "Separation - Partial Ejection" has elapsed, a partial
ejection is initiated automatically which is then repeated at identical intervals.
Before each partial ejection the solenoid valve C "Hood flush water" opens for
approx. 10 seconds. This time can be preset as the program time "Pre-flushing".
Water is sprayed into the hood to prevent the solids to be ejected from sticking
to the walls.
For solids ejection the solenoid valves B "Closing water" and D "Opening water"
open for 1 second. This time can be preset as the program time "Partial ejec-
tion".
The solenoid valve B "Closing water" remains open for a further 5 seconds after
the ejection. The time is set via "Closing". At the same time the hood flush water
valve stays open for the time "Post-flushing".
The "Separation" program can be interrupted by pressing the "Partial ejection"
button. A partial ejection is then triggered. After termination of this forced partial
ejection the control program automatically switches back to "Separation".
Before each partial ejection the "Fine Tuner" is contracted to a small centripetal
pump diameter (see 6.4.2-"Ta").
After each ejection the centripetal pump is extended to the large centripetal
pump diameter after time (see 6.4.2 - "Tb").
These times are adjustable.

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Setting the program times:

Program times... sec are process-related and must be set before start-up.
Program time
Pre–flushing approx. 10 secs
Pre–flushing hood/solids collector.
Partial ejection 1 sec
This determines the opening time of the
opening–water valve. This time must be
longer than the displacement time of the
opening water from the
metering unit.
The ejected solids volume depends on
the preset volume in the metering unit.
Secondary flushing approx. 20 secs
Flushing the hood and solids collector
after an ejection.
Closing 5 sec
Closing water addition after an ejection.
Metering device 3 secs
Continued control of air for metering
device after partial ejection.
Filling water 2 secs
Delayed filling water supply after partial
ejection.
Total ejection 10 secs (not variable)
Addition of opening water during total
ejection.
Waiting approx. 60 secs
Waiting time after total ejection for
speed recovery of bowl.
Delay ejection after con- Capacity–dependent 1)
tracting centripetal pump Displacement of the separating zone to
(Ta) the centre to enable more heavy phase
to enter the bowl.
Delay centripetal pump Capacity–dependent 1)
travel–out after ejection Filling the bowl with heavy phase.
(Tb)
Centripetal pump travel–out Capacity–dependent 1)
delay (Tc) When product is first fed into the bowl,
the bowl must be filled with heavy
phase to the extent that there is no
carry–over when the centripetal pump is
extended.

1) The higher the capacity, the shorter the time.

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6.4.2 Function diagram of partial ejection

Program times

Fig. 98

Setting the program times: See control unit manual

1) When the waiting period for resuming the bowl speed has
elapsed, no automatic switch–over to ”separation” will take
place.
2) These functions are provided in the control unit and can be
adjusted if an automatic water valve has been installed.

Ta Delay of ejection after contracting the centripetal pump)

Tb Delay in extending the centripetal pump after ejection
Tc Delay in extension of centripetal pump (after starting with
product).

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6.4.3 Total ejection

During cleaning-in-place total ejections can only be initiated manually with the
control unit. (Automatic cleaning-in-place requires a separate CIP unit, see rele-
vant brochure.)
During a total ejection the whole bowl contents are ejected.

Never initiate a total bowl ejection when the machine is vibrating severely
(bowl unbalance).
Attention!
To trigger a total ejection, press function key "Total ejection".
If the installation is correctly set up (see connection diagram of control unit), the
feed pump is automatically switched off by pressing push button "total ejection"
and automatically re-started approx. 1 min. after completion of the total ejection.
The interruption of the feed to the bowl by switching off the feed pump is neces-
sary for the bowl speed to recover, which drops slightly during total ejections.
Once the bowl has been filled again (observe increasing discharge pressure of
centrifuge), a further total ejection can be carried out by again pressing push
button "total ejection".
Should the feed pump fail to stop automatically during a total ejection, it must be
switched off manually and re-started 1 min. after total ejection.

6.4.4 Bowl ejection (manual)

In the case of control unit failure or
defective solenoid valves the separa-
tor can be controlled manually:
Partial ejection
Open closing water valve B and filling
valve A with the hand actuated lever.
Open opening-water valve D briefly
(approx. 1 sec).
After the partial ejection leave closing-
water valve B open.
Total ejection
Switch off the product pump.
Open closing water valve B and filling
valve A with the hand actuated lever.
Open opening-water valve D with the
hand actuated lever until the ejection
noise
has died down. Close opening water
valve D and filling valve A; leave clos-
ing water valve B open.
Switch on the product pump again 1
minute after the total ejection.

Fig. 99

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6.5 Adjusting the separation efficiency

To achieve perfect separation of the liquid mixture, the bowl must be adjusted to
the different densities.
To do this,
– first adjust the "Fine Tuner" (6.5.1)
– and then the hydrohermetic feed system (6.5.4).
– Then carry out final adjustment of the "Fine Tuning" (6.5.5).

6.5.1 Adjusting the "Fine Tuner"

The bowl is adjusted to the different densities of the mixture by altering the di-
ameter of the "Fine Tuner".
The required diameter of the "Fine Tuner" can be determined using the formula
below.
The general rule of thumb is:
Small "Fine Tuner" diameter with a low density difference,
Large "Fine Tuner" diameter with a large density difference.
When separating pasty substances, the diameter of the "Fine Tuner" not only
depends on the densities of the two components but also on the flow character-
istics of the heavy component.
In almost all cases a larger diameter of the "Fine Tuner" should be selected than
is actually required by the difference in densities of the light liquid and the heavy
pasty component.

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6.5.2 Calculation of the "Fine Tuner" diameter

The diameter of the "Fine Tuner" can be determined with the aid of the formula
below.
It should be noted that the densities are dependent on the temperature. To de-
termine the "Fine Tuner" diameter, those densities must be entered that corre-
spond to the separating temperature.
gheavy phase = 1.0484 kg/dm3 Doil – centripetal = 120 mm (im-
pump mersed)
3
goil = 0.88 kg/dm Dseparat- = 426 mm (centre
ing zone rising channel)

! heavy phase (D separating zone ² - D heavy phase ²) " ! oil (D separating zone ² - D oil ²)

Dheavy phase = D"Fine Tuner":

! oil
D heavy phase " D separating zone ² # $ ( D separating zone ² # D oil#centripe ² )
! heavy zone

Whether the correct diameter for the "Fine Tuner" has been selected can be es-
tablished by checking the position of the separation zone which forms between
the light and heavy phase in the bowl. The middle of the separating zone is the
separating line; it is almost always visible on the underside of the disks after
opening the bowl. It is sufficient to check a few of the uppermost disks.
The separating line should be situated in the outer third of the rising channels.

6.5.3 Presetting separation

Setting the separation on the machine is done by entering the desired centripe-
tal pump diameter on the control unit.
The selected centripetal pump diameter should initially be slightly smaller than
needed. This procedure provides less risk of carry-over when the hydrohermetic
feed is adjusted in the next step.
Setting possibilities:
Input of the large centripetal pump diameter: max 245 mm
– The working diameter of the "Fine Tuner" is adjusted (calculated from
6.5.2), i.e. separation takes place in this position.
Input of the small centripetal pump diameter: min. 172 mm
– The position is defined to which the "Fine Tuner" travels during start-up and
solids ejection.
The standard value is a diameter of approx. 185 mm.

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6.5.4 Adjusting the hydrohermetic feed

Fig. 100

The values shown in the diagram are based on measuremens with turbine oil
and water. They should be considered as reference only. When treating other
products, the range of operation might be different.
Determine feed capacity.
Determine feed pressure from the above diagram.
Adjust the determined feed pressure by throttling the light-phase (oil) dis-
charge.
Note:
– If the feed pressure exceeds the permissible value Pmax, there will be an
overflow into the heavy phase.
– if the pressure falls below Pmin, the system is not sufficiently filled, the hy-
drohermetic feed does not work.

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6.5.5 Final adjustment of separating efficiency

After having finally adjusted the hydrohermetic feed, carry out final adjustment
of the "Fine Tuner".
Set the optimum separating efficiency by entering the large centripetal pump
diameter.

- The light phase contains part ය Increase the diameter of the ”Fine
of the heavy phase. Tuner”.
- The heavy phase contains part ය Reduce the diameter of the ”Fine Tuner”
of the light phase. or check the discharge pressure to make
sure that no overflow from light to heavy
phase has occurred.

Note:

The light phase centripetal pump is only needed for adjusting the hy-
drohermetic feed.
Attention!
– The hydrohermetic feed is throughput-dependent, i.e. it has to be read-
justed when the throughput changes.
The "Fine Tuner" is intended for setting the separating zone.

6.6 Product mode

Prior to feeding oil, supply cold or hot water to the bowl, depending on
the process, until the separating temperature is reached (this is of particular
importance when treating oils that tend to emulsify easily).
Then stop the process water supply.
The water forms a water seal in the bowl which prevents the oil from discharg-
ing through the water outlet.
Open the hand shut-off valve in the product feed line, if provided.
Press „Product ON" key:
– Switch on the separation program.
– Oil metering pump on or product valve open.
Adjust the throughput capacity.
– The "Fine Tuner" is positioned for a small centripetal pump diameter. Carry-
over is thus prevented.
As soon as enough heavy phase has formed inside the bowl, the centripetal
pump is positioned for a large diameter. The period to be provided for this
step can be preset (see 6.4.2).
Throttle the pressure in the oil discharge line so that the hydrohermetic feed
works.
Carry out final adjustment of the "Fine tuner" (6.5.5).
After the pressure switch on the clean oil side has responded the LED „PAL"
goes out. Monitoring of the clean oil discharge is disabled for the program
time „delay discharge pressure". The program time starts with „Separation".
If the pressure switch responds during separation, the product feed valve
closes automatically or the oil metering pump is switched off and the separa-
tion program is interrupted.
The LED „PAL" flashes.
Be sure to feed process water again before restarting with product.

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The throughput capacity of the separator (i.e. supplied liquid volume per
unit of time) depends on
– the viscosity,
– the temperature,
– the difference in densities of the components to be separated,
– the nature of the heavy component to be separated,
– the desired degree of purity of the light component.
In the case of longer interruptions in operation, e.g. due to no product supply,
we recommend carrying out one or two partial ejections by pressing the „Par-
tial ejection" key to avoid compacting of the heavy phase in the bowl.

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 mate-
Attention!
rial.

The separation program including the partial ejections is carried out automati-
cally by the control unit.
The running program can be interrupted by pressing the „Partial ejection" key
which triggers a bowl ejection immediately.
The function diagram shows the program sequence for partial and total ejec-
tions.
The program sequence is indicated in the mimic diagram of the control unit by
means of LEDs.

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6.7 Shut-down (Normal Off)

Press function key "Separator 0".
Product feed pump off.
– Product feed valve closes.
– Braked run-down of separator through frequency converter with feedback
facility.
– Signal "operation" goes out.
– Total ejection takes place.
– Valves in the separator discharges are opened (control air bled from con-
stant pressure valves).
– The lubricating oil unit switches off at a certain bowl speed (see data
sheet).
– Signal "bowl standstill".

Do NOT loosen any part of the separator before the bowl is at a standstill!

Danger of injury to persons through rotating bowl parts.

CAUTION!

6.8 Shut-down (Emergency-Off)

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

Do not supply opening water!

– Product feed valve closes.
– Braked run-down of separator through frequency converter with feedback
facility.
– Run-down water valve open (max. 20 m3/h).
– Switch-over in the separator discharge from product path to sewer.
– Valve in separator discharge is open (control air bled from constant pres-
sure valve).
– Separation program off.
– The lubricating oil unit switches off at a certain bowl speed (see data
sheet).

At bowl standstill
– Run-down water valve closed.
– Signal "bowl standstill".

Do NOT loosen any part of the separator before the bowl is at a standstill!

Danger of injury to persons through rotating bowl parts.

CAUTION!
When shut-down (Emergency-Off) is caused by vibration,
Open and clean bowl before re-starting.

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Check if bowl is correctly assembled and check drive.

Observe safety precautions when carrying out maintenance work!

6.9 Run-down (overspeed)

– Product feed valve closes.
– Main motor off.
– Switch-over in the separator discharges from product path to sewer.
– Valves in the separator discharges are opened (control air bled from con-
stant pressure valves).
– Separation program off.
– The lubricating oil unit switches off at a certain bowl speed (see data
sheet).
At bowl standstill
– Signal "bowl standstill".

Do NOT loosen any part of the separator before the bowl is at a standstill!

Danger of injury to persons through rotating bowl parts.

CAUTION!

After shut-down through overspeed before renewed start-up

– Open and clean the bowl.
– check programmed output frequency on the frequency converter,
– check transmission ratio of the drive,
– Check speed limit value setting on the operator panel,
– Check control electronics on the frequency converter.

6.10 After shut-down

Close hand shut-off valves in the feed and discharge of the separator.
Close manual shut-off valves in supply lines for
– operating water,
– control air,
– cooling liquid,
– hood flush water,
When the machine is shut down for prolonged periods, follow the instruc-
tions in the chapter “Cleaning”!

6.11 Prior to a long-term shut-down

If the separator is not operated for a prolonged period, a number of basic points
must be observed. Only in this way can it be ensured that no damage occurs to
the separator when it is later put back into operation. The exact procedure for
preparing a separator for a prolonged shut-down is described in the chapter
cleaning.

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90 Westfalia Separator AG

6.12 Trouble shooting

Short-term mains failure
Product feed valve closes.
Main motor OFF.
Separation program OFF.
Automatic valves close.
When power returns
Press "reset" function key.
Press "Separator I" function key.
After switching to "Operation" two total ejections are carried out automatically.
Note: The machine is shut down (Emergency Off) before pressing the Reset"
key.
Long-term mains failure with bowl standstill
Product feed valve closes.
Main motor OFF.
Separation program OFF.
Automatic valves close.

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

Open and clean bowl before re-starting.

Note safety precautions when carrying out maintenance work!

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Westfalia Separator AG 91

Faults Causes Automatic Remedies

responses
Motor temp. stage 1 Motor overloaded. Visual and audible alarm. Extend ejection intervals,
C
(160 o ) Motor defective. reduce throughput capacity.
TAH Ejection intervals too short. Check that bowl is tight, water
Ambient temperature too high. and mechanical brakes are
No or insufficient motor cool- serviceable. Check motor
ing. current:

Observe ammeter.
If motor current is too high,
check drive.
Let motor idle and check after
approx. 15 minutes if the signal
can be acknowledged by
pressing the ”reset” button.

If that is the case, the motor

temperature has dropped.
Then perform a total ejection
and check if motor fan system
is dirty.
If necessary, shut down the
Separator and clean external
fan.
Motor temp. stage 2 No remedial action was taken Visual and audible alarm. Check drive.
C
(180 o ) after fault indication Stage I”. Main motor OFF. Check motor.
TAH Motor overloaded. Separation program OFF.
Drive defective. Product valve closes or
Motor defective. product pump off.
Total ejection
Overcurrent Bowl leaks. Visual and audible alarm. Check if
IAH Bowl rotates in solids. Main motor OFF. – bowl is tight,
Water brake is in operation Separation program OFF. – solids discharge is blocked,
.Drive defective. Product valve closes or – bowl rotates in solids.
Motor overloaded. product pump off. Clean solids collector and
Single phase run Total ejection frame
.Motor defective.
Check that water brake is
serviceable (solenoid valve for
brake water leaks).
Check motor.
Check drive.
Vibration stage 1 Unbalance of bowl due to Total ejection While the bowl is filled perform
22,5 % = 4,5 mm/s uneven solids ejection or due Visual and audible alarm. several partial ejections by
t > 10 sec NAH to incorrect assembly of bowl. pressing the respective button.
Drive defective (bearings or A 5 minute delay time starts
vibration absorbers) simultaneously.

If unbalance cannot be elimi-

nated during this time, separa-
tor is shut down via ”emer-
gency off”.
Vibration stage 2 Visual and audible alarm. Open and clean the bowl.
35 % = 7 mm/s Shut–down ”Emergency Off”.
t >5 sec NAH If bowl is not dirty and is cor-
rectly assembled, check drive
(bearings and vibration ab-
sorbers).

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92 Westfalia Separator AG

Faults Causes Automatic Remedies

responses
Fan [IMG,0,20,3,2]FL Fan motor defective. Visual and audible alarm. Main Check fan motor.
Fan motor overloaded. motor OFF. Clean fan.
Single phase run. Separation program OFF.
Fan motor off.
Product valve closes or
product pump off.
Total ejection

Lubrication FAL Lube oil flow interrupted. Visual and audible alarm. After Check lubrication system.
Lube oil level too low. 5 minutes: Check monitoring system.
Main motor OFF.
Separation program OFF.
Product valve closes or product
pump off.
Total ejection

Operating–water Water pressure <Pmin or water Visual and audible alarm. Check water supply system.
t >5 sec supply failure. Separation program OFF. Clean filter in pressure reducer.
Product valve closes or product If the water pressure drops so
pump off. far that the required water
pressure does not build up
within the max. possible sepa-
rating time and no ejection is
possible, the separator must be
shut down and the bowl
cleaned by hand. (If the per-
missible retention time of the
solids in the bowl is exceeded
– product–dependent – the
solids will harden and be
ejected unevenly from the
bowl. The result is severe
unbalance during ejection).

Speed min. RUN Bowl leaks. Visual and audible alarm. Carry out the following
Slippage of flat Separation program OFF. checks at operating speed:
belt. Starting time longer 12 Product valve closes or product
minutes. pump off. – bowl for watertightness
Water brake is in operation. – speed measuring device
Drive defective. – limit value setting on
speed indicator
– solenoid valve for water
brake

at standstill:
– drive
– flat belt, replace when nec-
essary

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Westfalia Separator AG 93

Faults Causes Automatic Remedies

responses
Ejection monitoring Water pressure too low. Visual and audible alarm. Initiate a solids ejection by
(The signal is activated Water filter blocked. Separation program OFF. pressing the ”Total ejection”
when there is no current Operating–water line Product valve closes or key and observe the ammeter.
increase when an ejection leaks. Nozzles in the operat- product pump off. Check water pressure.
is initiated. The speed ing–water feed are blocked. Clean filter in operating–water
drops during ejections. Bowl hydraulic system is defec- line. Check operating–water
Increased current con- tive. line for
sumption brings the bowl Operating–water valves leakage. Clean nozzles and
back up to operating defective. Opening time too bores in operating–water
speed.) short. feed. Check operating–water
Air supply to metering device valves. Check air supply to
not operational: metering device.
– pressure reducer
– 3/2–way pilot valve
If still no success,
shut down separator!
Check bowl hydraulic system
and renew gaskets if neces-
sary.

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94 Westfalia Separator AG

Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note

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Westfalia Separator AG 95

7 Cleaning

7.1 Cleaning-in-place...................................................................................96
7.2 Bowl .......................................................................................................99
7.3 Frame...................................................................................................100
7.4 Operating water feeding device...........................................................100
7.5 Cleaning the lube-oil vessel .....................................................................100
7.6 Prior to a long-term shut-down ............................................................101
7.7 Note on cleaning work on hoods .........................................................102
7.8 Note on cleaning work on disks...........................................................102

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96 Westfalia Separator AG

7.1 Cleaning-in-place
After use, the separator must be cleaned in place.
During CIP, cleaning solution is circulated through the separator and the con-
nected system.

Attention:
Make sure that the cleaning solution emerging from the discharge lines of the
separator cannot enter the product lines.
Set changeover valves, if provided, accordingly.
If no changeover valves are provided, the plant has to be modified accord-
ingly.
To prevent corrosion damage, only approved detergents should be used.
Example: Henkel - 2 % lye (P3 Super LA)
Bayer - 2 % caustic (Trosilin M alkaline)
- Acid solution 0.5% (Trosilin M acid)

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Westfalia Separator AG 97

The following cleaning program is recommended:

Program sequence Duration of the
individual program
steps

1. Pre–flushing Feed rate: approx. 5 m3/h 2 - 5 minutes

Displacing the product with hot water

2. Caustic flushing
temperature: 70 - 80 oC
Feed rate: approx 5 m3/h
2 percent caustic solution (NaOH) (caustic
soda free of chloride)
Dislodging residual dirt 20 minutes
Purging the piping with water
Overflow

3. Intermediate flushing
temperature: 70 - 80 oC
Feed rate: approx. 5 m3/h
hot water 2 -5 minutes
total ejection

4. Neutralizing
Temperature: 65oC
Feed rate: approx. 5 m3/h
Neutralizing with 0.5 % HNO3 solution 20 minutes
Purging the piping with water
Total ejection

5. Post-flushing
Temperature: 70 - 80 oC
Feed rate: approx. 5 m3/h
Flushing out the HNO3 solution with water 5 minutes
Total ejection approx. 30 seconds

The total ejections must be initiated by pressing a button.

The commands “Total ejection" can be automatically triggered from an external
CIP control unit.

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98 Westfalia Separator AG

Feed

Light phase discharge

Heavy phase discharge

Pressure mea-
surement

Fig. 101

To obtain perfect cleaning of the bowl, the system has to be connected as fol-
lows:
The CIP solution is fed into the feed.
The liquid emerging from the heavy-phase discharge is diverted into the oil
discharge unthrottled. Thus, an internal circuit is formed whose throughput
rate is greater than the feed rate. The volume that is fed flows off through the
light-phase discharge.
The oil discharge towards the tank is throttled (V3) as far as the motor current
allows, or until overflow of the bowl occurs (Inom of drive motor - see name-
plate).
The volume of circulating liquid is set only by means of the oil valve V3.

To prevent overload of the motor, the rated current (Inom) must not be ex-
ceeded.
Attention!

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Westfalia Separator AG 99

7.2 Bowl
Cleaning of the bowls after separation is only required when the nature of the
separated solids necessitates it.
Experience will show how often the bowl has to be cleaned.
The following points should be kept in mind:
During the first few months of operation, the lock rings should be removed
approximately every two weeks for greasing the threads to prevent seizing.
Later on, the greasing intervals may be extended.
However, the bowl should be dismantled at least every two months for thorough
cleaning of the inner bowl parts.

Never use metal scrapers or metal brushes for cleaning the discs and bowl
parts.
IMPORTANT

All bowl parts have fine tolerances; it is therefore important that all parts are
cleaned thoroughly and are free from burrs.
Remove the gaskets from the bowl parts.
Clean grooves and gaskets to prevent corrosion.
Replace damaged or very swollen gaskets immediately.
Swollen gaskets should be left to dry in a warm place so that they can regain
their original dimensions and can be re-used.
Carefully clean the small holes in bowl bottom and the two bowl valves for the
supply and discharge of the operating-water to ensure trouble-free perform-
ance of the solids ejections.
Clean and wipe dry guide surfaces and threads of bowl parts and grease
them.
Spindle cone and inside of bowl hub should be oiled and then wiped clean
and dry with a smooth rag.
The solids catcher and solids collector bottom should also be cleaned every
time.
Re-assemble bowl immediately after cleaning.
Otherwise the bowl parts must be protected against dust and dirt.

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100 Westfalia Separator AG

7.3 Frame
When cleaning the frame:
Never expose the machine to a direct water jet. It must be cleaned by hand,
with a sponge or cloth.
This applies especially to the motor, even if it is enclosed.

7.4 Operating water feeding device

The strainer in the water pressure reducer and the small holes in the operat-
ing water feeding device should be cleaned when necessary.

7.5 Cleaning the lube-oil vessel

The lube oil vessel on the external lube oil unit has to be cleaned at regular in-
tervals and
after several oil changes, but after the number of operating hours stated in the
“maintenance schedule” at the latest
when the oil has to be changed because water or dirt has seeped into the
drive,
when the oil circulation decreases (pressure drop in the oil circulation line
In this, case, the oil lines and channels in the drive have to be cleaned as
well.
Procedure:
– Loosen the lube oil advance and return lines.

For more instructions for cleaning the lube oil vessel, refer to the instruc-
tion manual of the external lube oil unit.
Instruction manual

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Westfalia Separator AG 101

7.6 Prior to a long-term shut-down

Thoroughly clean the separator bowl and frame (see chapter “Cleaning”)

Preserving the separator:

Drain the lubricating oil.
Fill the oil pan with a slushing oil, e.g. SHELL Ensis Fluid E or equivalent up
to middle of sight glass. In the case of separators with an external lubricating
oil unit, fill the lubricating oil vessel in accordance with the instructions in the
“external lubricating unit manual”.
Let the separator run with bowl until all the drive parts are coated with slush-
ing oil. (Observe start-up instructions!)
Remove the bowl from the spindle (see chapter “Bowl”).
Oil the upper end of the spindle by hand.
Permanent corrosion protection for separator drive parts with the specified
slushing oil can be guaranteed for a maximum of 1 year. After this time, the
bearings must be replaced as specified in the maintenance schedule.
Wipe dry and grease all bowl parts and all unvarnished machine parts.
The clean, grease-coated bowl should be kept in a dry place until it is used
again.
Remove all the gaskets and the drive belt and keep them in a cool, dry room,
protected from dust and light, to prevent them from getting brittle.
Check water shut-off devices for leakage.
If necessary, disconnect water supply lines to avoid damage caused by drip
water.
Switch off the operating water supply (if fitted) at the mains to prevent inrush
of water caused by inadvertent opening of the shut-off valve.
Before re-starting:
Drain the slushing oil.
Fill the oil pan with lubricating oil (see chapter “Lubrication”). In the case of
separators with an external lubricating oil unit, fill the lubricating oil vessel in
accordance with the instructions in the “external lubricating unit manual”.

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102 Westfalia Separator AG

7.7 Note on cleaning work on hoods

The following instructions must be followed during cleaning and maintenance

work on hoods.
Load suspension devices such as lifting devices for bowl or hood may
only be used correctly and properly and for the intended purpose only.
This means that work must be carried out as described in the separator
manual.
Caution
Do not use damaged or incomplete load carrying equipment.
Special safety precaution when
turning over the hood:
Unintended swinging or overturning
of the hood must be prevented.
Use the carrying straps as illus-
trated.
The minimum lifting capacity of the
carrying strap must be double as
high as the weight of the hood even
under consideration of the applica-
tion conditions.

Fig. 102

7.8 Note on cleaning work on disks

When mounting the disks, they are centrically guided over the distributor neck.
If disks are dismantled in connection with servicing / manual cleaning and are
stacked on one another outside the distributor, it must be ensured that the oni-
cal disk surfaces do not slide into each other.
To avoid damage, the disks should also be stacked centrically.

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Westfalia Separator AG 103

8 Drive

8.1 Drive.....................................................................................................104
8.1.1 Special risks of a separator .................................................................105
8.1.2 Safety precautions for maintenance and repair...................................108
8.2 Fitting and removing the motor............................................................112
8.2.1 Removing the motor ............................................................................112
8.2.2 Installing the motor ..............................................................................113
8.3 Removing spindle assembly, supporting disk......................................114
8.4 Dismantling the spindle assembly .......................................................116
8.5 Assembling the spindle unit .................................................................118
8.6 Replacing the rubber-metal bushes and the rubber cushions.............121
8.7 Installing the spindle assembly............................................................123
8.8 Adjusting the proximity switch .............................................................124

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104 Westfalia Separator AG

8.1 Drive
All work on the drive may only be carried out by specialists authorized by
Westfalia Separator.
Before carrying out maintenance or
repair work on the motor, bear in
mind that there may still be residual
voltage.
For this purpose,
– read the operating instructions
given by the manufacturer of the
frequency converter,
Caution
– have the appropriate measures
taken by specially trained staff.

Fig. 103

During all work on the drive, disconnect the power to the separator and
secure against re-starting!
Replace damaged gaskets immediately!
Caution

Before removing separator parts, their fitting position must be marked. This
eliminates later problems caused by fitting the part in the wrong position.
Before fitting, the grease must be removed from all contact surfaces of the slide-
ring packings.

Since slide-ring packings are easily destructible, they may only be fitted
by specially trained personnel.
Attention!
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 availability!

Therefore, only genuine original spare parts may be used!

Attention!

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Westfalia Separator AG 105

8.1.1 Special risks of a separator

The separator is equipped with a high-speed rotating metal bowl which repre-
sents 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.

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!
CAUTION!
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 standstill indication will pro-
vide false information because, for example, the electronics have failed or the
belt or gearbox 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 of gear separators
Optical speed check of the drive motor
Noise check
Vibration check
If you are not sure whether the machine is at a standstill, you must wait for the
run-down time specified in the separator documentation. A subsequent check is
carried out when you are sure that the machine is at a standstill.
Visual speed check by opening the inspection ports on hood and frame
Removing the inspection port in the separator hood enables you to look directly
on to the bowl. In addition, checking is also possible by removing the gearbox
cover or opening the port in the frame.

Only when you are convinced that the separator is at a standstill can the
following checks be carried out for additional security.
NOTE

2325-9001-020 / 0806
106 Westfalia Separator AG

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. 104

Revolution visual check on ma-

chines with gearbox.

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. 105

Revolution visual check on ma-

chines with direct 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. 106

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Westfalia Separator AG 107

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.
NOTE

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

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

CAUTION! 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.

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

CAUTION! Danger of frostbite!

Depending on type and installation site, hazards in the form of noise

emission from the separator may occur. Therefore, always wear protective
gear in accordance with the national regulations.

CAUTION!
Danger of hearing damage!

During all maintenance and repair work on the separator, the fittings and
pipelines, there is the risk of injury due to spurting liquids, e.g. hot or
caustic liquids can spurt out under pressure.

CAUTION! Danger of causticization of skin and eyes!

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108 Westfalia Separator AG

8.1.2 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. Reduce the
maintenance intervals to adapt 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 main-
tenance schedule to assure safe and
efficient operation.

Fig. 107

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. 108

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

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Westfalia Separator AG 109

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. 109

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.

Do not heat bowl parts with a

naked flame to facilitate disman-
tling work.
Structural changes in the material of
the bowl parts which affect the operat-
ing safety of the machine may result!

Do not weld bowl parts.

Fig. 110






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

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110 Westfalia Separator AG

Place the dismantled separator

parts on suitable surfaces (rubber,
wood etc.).
Take appropriate steps to prevent
machine parts from overturning and
rolling away.

Fig. 111

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. 112

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 operated

when locking devices and marks on
the bowl parts are damaged.

Fig. 113

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Westfalia Separator AG 111

After fitting certain new 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 specialist workshops
authorized by Westfalia Separator!

If in doubt, consult the service de-

partment of Westfalia Separator.

Fig. 114

Unqualified balancing can lead to dangerous operating states and to de-

struction of the separator with danger to life and limb of the personnel.
CAUTION!

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

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112 Westfalia Separator AG

8.2 Fitting and removing the motor

Danger of injury through running machine!
Before carrying out work on drive and drive components:
– Set the main switch of the separator to "OFF”.
– Disconnect power to the motor control and
– secure both against switching back on!
Caution

8.2.1 Removing the motor

Take adequate measures to prevent
the motor from overturning.
Support it with a hoist (e.g. using a
fork stacker and a pallet as shown in
figure). The fan housing is designed
to hold this type of load.
Unscrew hexagon nuts 1.
Carefully let the motor touch down
with the hoist.

Fig. 115

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Westfalia Separator AG 113

8.2.2 Installing the motor

Slip clutch element 1 onto the motor

shaft as described in the manual for
the clutch.
Adjust the axial clearance S (gap
dimension); refer to the manual for
the clutch.
Locate the clutch on the motor shaft
by means of the adjusting screw.
Tighten screws of the clutch with
torque (greased screws) M = 37
Nm.

Fig. 116

Take adequate measures to prevent

the motor from overturning.
Lift it with a hoist (e.g. using a fork
stacker and a pallet as shown in fig-
ure).
Turn the clutch elements so that the
clutch ring (cam element) catches
into clutch element 1 (see Fig. 116 ).
Lift the motor with the aid of the
hoist. Make sure that the bolts for
fastening the motor catch into the
holes of the motor flange.
Screw on hexagon nuts 1 with in-
serted lock washer and tighten
firmly.
Check width of gap (see Fig. 116 )
and adjust if necessary. For this
purpose remove the motor as de-
scribed under “Removing the mo-
tor”.

Fig. 117

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114 Westfalia Separator AG

8.3 Removing spindle assembly, supporting disk

Removing the spindle assembly
Pull ring 1 with gasket by hand up-
wards off the spindle.
Remove cap nuts 2 with inserted
gaskets.
Lift out protective cover 3.
Disconnect hose connection 5 for
the spraying device.

Fig. 118

If the solids catcher has to be dis-

mantled:
Unscrew the screws for fastening
the solids catcher.
Screw the eye bolts 1 into the solids
catcher.
Lift off solids collector 2 together
with the chains.

Fig. 119

Disconnect hoses 1 and 2 from the

connections.
Loosen connector 3 of the connect-
ing cable towards the proximity
switch. The proximity switch can be
left in position.
Loosen the coupling nut 4 of the
bearing condition monitoring system
(optional).

Fig. 120

Remove hex head screws 1 (fasten-

ing rubber-metal bush) and hex
head screw 2 (fastening rubber
cushion).
Thread hex head screws 3
(M12x90) into the four puller holes
of the bearing housing and force off
the bearing housing by altenately
tightening the screws.

Fig. 121

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Westfalia Separator AG 115

Screw spindle lifter 1 into the

threaded hole of spindle 2 and lift
out the spindle unit.

Fig. 122

Remove hex head screws 1 from

the supporting disk.
Thread 4 hex head screws into the
tapholes and force the supporting
disk from the frame.

Fig. 123

Screw in 4 eye bolts 1 and lift off the

supporting disk with the hoist.

Fig. 124

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116 Westfalia Separator AG

8.4 Dismantling the spindle assembly

Undo Allen screws 1 on the oil col-
lector housing and lift off cover 3
and clutch ring 2.

Fig. 125

Remove securing ring 1.

Pull the oil collector housing 2 off
the spindle with the tool provided.
While doing so, slightly tilt the oil
collector housing because of the
protruding oil centripetal pump.

Fig. 126

Dismantle feather key.

Unscrew cylindrical screws 1 and
cams 2 (oil centripetal pump).

Fig. 127

Unscrew threaded pin 1.

Pull off sleeve 2 upwards.
Remove the gasket from the sleeve.

Fig. 128

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Unscrew Allen screws 1.

Screw two hex head screws 2 into
the tapholes of the housing 3.
Force off housing 3 by evenly tight-
ening the hex head screws 2.

Fig. 129

Carefully drive out the spindle to-

gether with the bearings by hitting
with a hammer.
Place a wooden block against the
shaft collar at the bottom of the
spindle.
Drive out the spindle until the angu-
lar contact ball bearings have be-
come dislodged from their seats.
Remove the spindle.

Fig. 130

Mount pressure disk to protect the

spindle 1.
Pull cylindrical roller bearing 2, dis-
tance sleeve 3, angular contact ball
bearing 4 and oil guide ring 5 off the
spindle using a commercially avail-
able puller.

Fig. 131

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8.5 Assembling the spindle unit

Each time before installing the bearings, make sure:
Use only bearings as specified in the Parts List.
Replace angular contact ball bearings and grooved ball bearings when they
show the slightest sign of damage, but at the latest in accordance with the
operating hours specified in the maintenance schedule .
The two angular contact ball bearings must always be replaced together.

Faulty mounting will inevitably result in irreparable damage to the bearing!

Attention!
The angular contact ball bearings may be loaded in one direction only.
Install the bearings as shown in Fig. 132 .
Prepare the spindle:
Clean holes.
Slip in oil guide ring 1 as far as it will
go.
Warm up angular contact ball bear-
ing 2 in oil to about 80 °C and slip it
on the spindle.
Watch for correct position!
Slip on the distance sleeve 3.
Warm up grooved ball bearing 4 in
oil to about 80 °C and slip it on the
spindle.
Insert gasket 5.
Insert key 6.

Fig. 132

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Carefully fit spindle 1 with bearing

as far as it will go into bearing hous-
ing 2.
Mount cam 3 (oil centripetal pump)
on the bearing housing with cylindri-
cal screws 4.

Fig. 133

Insert gasket 1 in housing 2.

Install housing 2 and fasten with
Allen screws 3.

Fig. 134

Insert gasket 2 in sleeve 1.

Mount sleeve 1. The bore of the
sleeve must be placed above the ar-
resting hole of the spindle.
Fasten sleeve 1 with Allen screws 3
and secure with Loctite 245.

Fig. 135

For installation, adjusting or maintenance work on the clutch, refer to the

instructions given in the clutch manual.
Instruction manual

Before mounting the oil collector housing, oil the spindle seat and wipe clean
and dry using a cloth.
Clean the inner bore of the oil collector housing to ensure a good fit.
NOTE

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Slip on the oil collector housing.

While doing so, slightly tilt the oil
collector housing because of the
protruding oil centripetal pump.
Install the oil collector housing to-
gether with the securing ring.

Fig. 136

Fasten clutch ring 2 and ring 3 on

the oil collector housing with Allen
screws 1.
(Torque 37 Nm)

Fig. 137

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8.6 Replacing the rubber-metal bushes and the rubber cushions

Removing the rubber-metal bushes:
Place bolt 1 on ring 2.
Press of rubber-metal bush 3 to-
gether with bolt 5 out of the support-
ing disk.

Fig. 138

With the aid of puller withdraw rub-

ber-metal bush over ring 4.

Fig. 139

Apply tube pliers only at the lower

metal support of the rubber cushion.
Remove rubber cushions 1.

Fig. 140

Replace vibration absorbers.

Insert ring 1.
Place bolt 2 on the outer ring of the
rubber-metal bush.
Press rubber-metal bush 3 into the
supporting disk.

Fig. 141

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122 Westfalia Separator AG

Place ring 1 on bolt 3.

Insert disc 2 between inner ring of
the rubber-metal bush and the base.
Press bolt 3 with bolt 4 into the rub-
ber metal bush.

Fig. 142

Apply tube pliers only at the lower

metal support of the rubber cushion!
Install rubber cushions 1 with the
tube pliers.

Fig. 143

Screw eye bolts 1 into the support-

ing disc.
Insert supporting disc into the frame
using the hoist.
Remove eye bolts 1 from the sup-
porting disk.

Fig. 144

Fasten the supporting disk in the

frame with hex head screws 1.

Fig. 145

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8.7 Installing the spindle assembly

Screw spindle lifter 1 into the spin-
dle.
Install spindle assembly 2 in the
lower part of the frame with a suit-
able hoist.
Unscrew spindle lifter 1.

Fig. 146

Fasten the spindle assembly to the

rubber metal bushes with Allen
screws 1 and to the rubber cushions
with Allen screws 2.
Connect hoses 3 to the respective
connections.
Insert connector 4 of the connecting
cable into the proximity switch (op-
tional).
Connect vibration pickup 5 (op-
tional) for the bearing condition
monitoring system.
Fig. 147

Place the operating water feeding

3 device 2 on the spindle. Pay atten-
tion to correct positioning.
Screw in and tighten hex head
screws 1.
Introduce and screw tight the hoses
for the operating water feeding de-
vice 2 at the connections 3.

Fig. 148

Screw the eye bolts 1 into the solids

catcher.
Place solids catcher 2 on the frame.
Fasten to the frame using the hex
head screws.

Fig. 149

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Mount protective hood 7 and fasten

with cap nuts 1 and hex head
screws 3 with gaskets 2 and 4.
Fit ring 6 with gasket and fasten with
hex head screws 5.
Slide the clutch onto the spindle
from below and secure against slip-
ping with the retaining ring.

Fig. 150

8.8 Adjusting the proximity switch

If necessary, adjust switching dis-
tance A 1 mm ± 0.2 as follows:
Screw the proximity switch 1 (M
14x1) as far as it will go onto spindle
cap 2, then screw back by a com-
plete turn and lock with a hexagon
nut. This ensures the correct switch-
ing distance.

Fig. 151

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9 Trouble shooting

9.1 Mechanical function .............................................................................126

9.2 Clarifying function ................................................................................130

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9.1 Mechanical function

Fault Possible causes Remedies

The bowl does not come up to Motor is incorrectly connected. Check connection
rated speed or takes too long to
do so (see chapter "Motor con-
nection").

Water brake in operation Check brake water valve.

The frame drain is blocked. Check the operating water discharge,

Liquid or dirt has accumulated in the liquid must run off freely. Clean the
frame pot, thereby braking the bowl. frame beneath the bowl.

Clutch ring defective or insufficiently Replace clutch ring or check its fas-
fastened. tening arrangement.

Oil collector housing slides on the Check fastening of oil collector hous-
spindle. ing (see chapter “Drive”).

Product feed is open. Close product feed.

The bowl speed drops during Motor speed drops during operation. Check motor and line voltage.
operation.

Bowl leaks (current consumption is Check the gaskets in the sliding pis-
too high). ton, bowl top and bowl bottom.

Clutch defective. Replace the clutch ring (see chapter

“Drive”, section “Removing the motor”
and “Assembling the spindle unit”).

Main bowl gasket in bowl top is Replace gasket (see 4.6).

damaged.

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Fault Possible causes Remedies

Uneven run of the separator. Bowl is out of balance. For pos. 1 - 4:
Stop the separator immediately.
Open the water feed.

The bowl may not be emptied as other-

wise the vibrations occurring during run-
down would intensify.
Causes:
1. Solids have deposited
unevenly in the bowl and
are partially not ejected
because
D solids structure is too
firm,
D solids are fibrous or Clean the bowl (4.7).
contain coarse impuri- Pre-strain the product.
ties,
D solids are earthy or
sandy or cake together,
D Ejection intervals are Readjust on control unit.
too long. Shorter ejection intervals.
2. Bowl is not correctly as- Assemble bowl properly (see chapter
sembled or parts of differ- 4.4).
ent bowls have been inter-
changed.
3. Tension of disc stack has Make sure bowl lock ring is screwed on
slackened. tightly (see 4.4).
A loose lock ring can endanger life.
Check number of disks. If necessary,
add spare disk or compensating disk.
4. The bowl is damaged and, Send the bowl to the factory for repair.
therefore, out of balance. Do not make your own repairs. Do not
weld or solder as this would weaken the
bowl material – danger to life!

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Fault Possible causes Remedies

Uneven run of the separator. Rubber-metal cushions in drive Change the rubber-metal cush-
(Cont’d) are fatigued. ions (see chapter “Drive“).

Rubber-metal cushions in drive Replace rubber-metal cushions

are fatigued. (see chapter “Drive”).

Angular contact ball bearings or Replace damaged bearings.

cylindrical roller bearings are CAUTION:
worn. Use only bearings as specified
in the Parts List.

Angular contact ball bearings or Replace damaged bearings.

cylindrical roller bearings are Clean the lubrication system
damaged due to inadequate (see chapter “Cleaning”)
lubrication because the suction
pipe in the spindle is clogged.

Discharging operating water is The ejected solids are too con- Perform several successive total
dirty. centrated with the result that ejections manually on the con-
they cannot discharge from the trol unit to flush free the solids
solids catcher into the discharge catcher. Shorten the ejection
pipe. intervals.
Solids rise in the catcher and Increase the ejection volume.
flow over into the frame to the
operating water discharge.

Current consumption too high. Bowl leaks. Check the gaskets in the bowl
top, sliding piston and bowl bot-
tom.

Solenoid valve for closing water Check solenoid valve.

defective.

Oil monitoring alarm Oil level is too low. Top up oil.

Lube oil bores of spindle as- Remove the spindle assembly

sembly or hoses clogged or (see chapter “Drive”), clean the
defective. holes in the drive spindle and
hoses. Check hoses for leakage
and replace, if necessary.

Oil filter clogged. Check the lubricating oil unit and

clean according to the instruc-
tions in the instruction manual.

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Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note

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9.2 Clarifying function

Fig. 152

1 Sliding piston A Solenoid valve filling water

2 Closing chamber B Solenoid valve closing water
3 Bowl valve C Solenoid valve hood flush water
4 Bowl bottom D Solenoid valve opening water
5 Gasket (sliding piston) E Metering device
6 Gasket (bowl top) F Non-return valve
7 Main bowl gasket G Water pressure reducer
8 Sealing rim (sliding piston) M Pressure gauge (opening water)
10 Gaskets (bowl bottom) N Pressure gauge closing water
11 Operating water feeding device
12 Gasket (operating water)

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Westfalia Separator AG 131

Fault Possible causes Remedies

Ejected solids contain too much Ejection volume too large. Reduce ejection volume.
process liquid.

Bowl leaks. See following sections.

The bowl does not close. Not enough operating water is

supplied because
CAUTION:
Water pressure in the line to the Check line pressure.
operating water connection is
In this case close the product too low.
feed and interrupt the separation The pressure with open valves
program. must be min. 2 bar.

Water discharge holes in top of Clean holes.

operating water feed are par-
tially blocked by scale.

Strainer in water pressure re- Clean strainer.

ducer G of operating–water line
is clogged.

Operating water feed 11 is leak- Check lines, screw couplings

ing. and gaskets.

Operating–water feeding system Clean operating–water feeding

11 is blocked. system.

Gasket 12 is damaged or has Replace damaged gasket or fit

not been inserted. gasket.

Gaskets or gasket in bowl Remove valves (see 4.7). Re-

valves 3 defective. place damaged gaskets or gas-
ket.

Gasket 5 in the sliding piston is Replace damaged gasket.

damaged or it is frayed at the
edges (due to the up and down
motion of the piston). If only the edges of the gasket
are frayed and the gasket is
otherwise in good condition,
grind off the edges on an emery
wheel and re–use it.

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Fig. 153

1 Sliding piston A Solenoid valve filling water

2 Closing chamber B Solenoid valve closing water
3 Bowl valve C Solenoid valve hood flush water
4 Bowl bottom D Solenoid valve opening water
5 Gasket (sliding piston) E Metering device
6 Gasket (bowl top) F Non-return valve
7 Main bowl gasket G Water pressure reducer
8 Sealing rim (sliding piston) M Pressure gauge (opening water)
10 Gaskets (bowl bottom) N Pressure gauge closing water
11 Operating water feeding device
12 Gasket (operating water)

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Fault Possible causes Remedies

The bowl does not close and The gasket 5 has not settled Stretch the gasket if the pre–
open properly. against the outer sealing sur- tension
faces in the sliding piston. is too high.
Lightly grease the groove in the
sliding piston before inserting
the gasket.
Gasket 7 in the bowl top is dam- Replace gasket (see 4.6).
aged.
Gaskets 10 in the bowl bottom Fit or replace gaskets.
have not been fitted or are dam-
aged.
Gasket 5 in the sliding piston is Fit correctly dimensioned gas-
not accurate in height. ket.

The differences in height of a

gasket must not be more than
0,25 mm.
The sealing rim 8 of the sliding Replace sliding piston.
piston is damaged.
Bowl does not open at all or not Dry dirt or rubber shreds have Clean bowl parts.
completely. deposited between the guides of
sliding piston 1 and bowl bottom Round off edges of gaskets.
4. Replace damaged gaskets;
grease guides with the special
lubricating paste.
Closing chamber 2 between Remove sliding piston 1 and
bowl bottom and sliding piston is clean the closing chamber.
dirty.
The holes in bowl valves 3 are Remove valves (see 4.7).
blocked. Clean holes.
No or not enough opening water
is fed to the bowl (master pres-
sure gauge M does not deflect)
for the following reasons:

The non–return valve F is dirty Clean or replace the non–return

or defective. valve.
Solenoid valve A or D is defec- Replace solenoid valve.
tive
Air pressure for metering device Increase air pressure to 4 bar.
E too low.
Opening times of the solenoid Check program times on control
valves are incorrectly set. unit (see function diagram).

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Fault Possible causes Remedies

The bowl opens during separa- Solenoid valve B is defective. Check solenoid valve.
tion.

No closing water pulses. Check control unit and closing–

water valve. Check control unit
and closing–water valve.

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10 Lubrication and maintenance

10.1 Lubrication schedule............................................................................136

10.2 Maintenance schedule.........................................................................137
10.2.1 Guide to ordering spare parts..............................................................138
10.2.2 Use of non-genuine spare parts ..........................................................139

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10.1 Lubrication schedule

Lubricant Lubrication interval Lubricant qty. Lubrication point

Lubricant as required apply thin coat All threads, fittings and contact
KSB 8 / WSF surfaces as well as manually
operated parts like brake bolts,
valves, tools etc.
Ceramic paste as required apply thin coat Bowl lock ring
Güsol-Anti-Seize
(If supplied)
Lubricant as required apply thin coat Gaskets
KSB 8 / WSF
Silicon grease as required apply thin coat All EPDM gaskets
Paraliq GTE-703 (If applicable)
as per manufacturer specs accord. to manufact. Accord. to manufact. Motor bearings
on motor nameplate instruct. instruct.
Gear oil See maintenance See data sheet With oil pan or external lubricat-
see Parts List, schedule ing oil unit depending on design
Roller bearing grease as required apply thin coat Neck bearing springs, spring
K3K pistons and pressure surface of
the clutch shoe backup.
(If applicable)
Steam turbine oil See maintenance In accordance with Fluid clutch
TDL 32 schedule specs in the docu- (If applicable)
mentation

Use only lubricants tested by Westfalia Separator for use on separators.

The use of non-genuine parts leads to:
– safety risks,
– less durability of these parts,
– reduced availability of the separator,
NOTE – increased maintenance requirement.

In this case, Westfalia Separator shall assume no liability or warranty.

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Westfalia Separator AG 137

10.2 Maintenance schedule

after operating hours every

OPERATIONS
250 1000 2000 4000 8000 day 3 6 1 2
mont mont year year
hs hs s

LUBRICATION SCHEDULE
Check oil level and circulation. D
D Oil change and thorough cleaning of the lube oil vessel (see also D
manual of external lubricating oil unit)*
D Grease manually-operated parts (brake bolt, valves, etc) D
whenever dismantling Grease threads, contact and guide surfaces of bowl parts (quan- whenever dismantling
tity approx. 50 g).
as per manufacturer specs on Grease motor ball bearings. as per manufacturer specs on
motor nameplate motor nameplate
MAINTENANCE SCHEDULE
Cleaning
Refer to manual of lubricat- D Clean the lubricating oil vessel of the external lube oil unit. D
ing oil unit.
D Clean bowl valves.
D Clean outlet bores of operating-water feeding device. D
D Remove bowl. D
Clean inner walls of frame solids catcher.
as required Clean strainer in pressure reducer in operating-water line. as required
product–dependent Dismantle and thoroughly clean the bowl. Be sure also to clean product–dependent
the bores and chambers of the hydraulic system.
Check
D Check starting time and rated speed. D
D Check bowl gaskets. D
Check the gasket grooves for corrosion.
D Check spindle bearings. D
whenever dismantling Check the flexible coupling packages. whenever dismantling
– wear
D Bowl inspection. D
Check all bowl parts and threads of lock rings for erosion and
corrosion.
product–dependent Check material between solids ejection ports. product–dependent
after each bowl unbalance Check all screwed unions. D
Replacement
D Replace all gaskets and seals. D
D Replace oil filter of low pressure filter. D
D Replace ball bearings of spindle. D
D Replace rubber-metal cushions and vibration absorbers. D
as required Replace the flexible coupling packages. as required
as per manufacturer specs on Replace motor bearing. as per manufacturer specs on
motor nameplate motor nameplate

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

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10.2.1 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 see pump nameplate

pump

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

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10.2.2 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. 154

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.
NOTE

2325-9001-020 / 0806
 Westfalia Separator AG
Take the Best – Separate the Rest

A company of GEA Group

Westfalia Separator AG Werner-Habig-Straße 1 D-59302 Oelde (Germany)

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

http://www.westfalia-separator.com/ mailto:info@gea-westfalia.de