SA 825 Separation System

Service Manual
Printed May 2002
Book No. 1810745-02 V 1
Alfa Laval reserves the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by: Alfa Laval Tumba AB
Marine & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2002.
Contents
1 Separator Design ................................. 1 2.8.4 Inspection for erosion .........................74
1.1 Overview .............................................1 2.8.5 Exchange of frame feet ........................76
1.2 The Drive Section.............................3 2.8.6 Lubrication of bowl parts ......................77
1.3 The Process Section .......................4 2.9 Assembly...........................................78
1.4 Sensors................................................8 2.9.1 Centrifugal clutch .................................78
1.5 Separating Function ........................9 2.9.2 Driving device ......................................82
1.5.1 The liquid balance in the bowl ...............9 2.9.3 Bowl ......................................................94
1.5.2 Liquid flow ............................................10 2.9.4 Frame hood ........................................107
1.5.3 Discharge of sludge and water ............10 2.9.5 Unbalance sensor (option) .................111
1.5.4 ALCAPTM concept................................11 2.10 Actions After Assembly..............113
2.10.1 Control of machine plates and
2 Separator Service, safety labels .......................................113
Dismantling, Assembly ................. 13 2.11 Oil Change ......................................115
2.1 Technical Data ................................13 2.11.1 Lubricating oil .....................................115
2.2 Connection List...............................15 2.11.2 Check oil level ....................................116
2.3 Interface Description ....................17 2.11.3 Oil change procedure.........................116
2.3.1 Scope ...................................................17 2.11.4 Lubrication chart.................................117
2.3.2 References ...........................................17 2.11.5 Lubricants...........................................118
2.3.3 Definitions .............................................18 2.11.6 Lubricating oils ...................................120
2.3.4 Goal ......................................................18 2.12 Lifting instructions ......................121
2.3.5 Description of separator modes ...........19 2.12.1 Lifting the separator............................121
2.3.6 Remote start .........................................20 2.12.2 Lifting the bowl ...................................122
2.3.7 Handling of connection interfaces .......20
3 Change of Circuit Board ............ 124
2.3.8 Interconnection diagram ......................27
3.1 Circuit Board
2.3.9 Electric motor .......................................28
Temperatures ................................126
2.4 Nomogram paring tube.................31
2.5 Maintenance ....................................33 4 Cleaning in Place ........................... 127
2.5.1 Periodic Maintenance...........................33 4.1 Cleaning in Place,
2.5.2 Maintenance intervals ..........................33 Separator ........................................127
2.5.3 Maintenance procedures .....................34
2.5.4 Tightening of screws ............................35
2.5.5 Service kits ...........................................35
2.5.6 Cleaning ...............................................36
2.6 Maintenance Log ............................37
2.7 Dismantling ......................................39
2.7.1 Introduction...........................................39
2.7.2 Tools .....................................................39
2.7.3 Frame hood ..........................................41
2.7.4 Bowl......................................................43
2.7.5 Driving device ......................................53
2.7.6 Centrifugal clutch .................................65
2.8 Actions Before Assembly ............71
2.8.1 Cleaning .............................................71
2.8.2 Inspection for corrosion ......................72
2.8.3 Inspection for cracks ..........................73

1810745-02
1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 1 SEPARATOR DESIGN

1 Separator Design

Process section
The feed inlet and outlets
are situated at the top of Electric motor
the separator. The rotating bowl is driven
by the electric motor via a
The liquid is cleaned in the belt transmission.
rotating separator bowl
inside the frame hood.

Sensors
Drive section
The separator is monitored
by a speed sensor. An The rotating separator
unbalance sensor and a bowl is driven by a flat
interlocking switch is belt transmission.
optional.

Frame feet
Sludge outlet
The separator rests
on vibration damping Separated solids are discharged at
frame feet. preset intervals.

G0870641

1.1 Overview
The separator comprises a process section and a
drive section powered by an electric motor.
The separator frame comprises a lower body and
a frame hood. The motor is attached to the
frame. The frame feet dampen vibration.
The bottom part of the separator contains a flat
belt transmission, a centrifugal clutch and a
vertical spindle. The lower body also contains an
oil sump for lubrication of spindle bearings.

1810745-02 1
1 SEPARATOR DESIGN SA 825 SEPARATION SYSTEM SERVICE MANUAL

The frame hood contains the processing parts of

the separator; the inlets, outlets and piping.
The process liquid is cleaned in the separator
bowl. The bowl is fitted on the upper part of a
vertical spindle and rotates at high speed inside
the frame hood. The bowl also contains the
discharge mechanism which empties the sludge
during operation.
A speed sensor and an unbalance sensor (option)
are part of the equipment for monitoring the
separator functions.

2 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 1 SEPARATOR DESIGN

1.2 The Drive Section

The separator bowl is driven by an electric
motor via a belt transmission. The belt pulley
on the motor shaft includes a centrifugal
clutch.

Flat belt
The flat belt transmission has a
ratio which increases the bowl
speed several times compared
with the motor speed.

To reduce bearing wear and the

transmission of bowl vibrations to The centrifugal clutch ensures a
the frame and foundation, the top gentle start and smooth acceleration,
bearing of the bowl spindle is and at the same time prevents
mounted in a spring dampened overloading of the belt and motor.
bearing seat.

The bearings on the spindle are

lubricated by the oil spray produced
by an oil pump mounted on the
lower end of the spindle.
G0870741

1810745-02 3
1 SEPARATOR DESIGN SA 825 SEPARATION SYSTEM SERVICE MANUAL

1.3 The Process Section

The separation process takes place inside
the rotating separator bowl. The feed and
outlet of process liquid takes place in the in
and outlet unit on top of the separator
frame hood.

Inlet and outlet

The inlet and outlet unit consists of the
following parts:
A connection house for pipe connections.
A pipe with a paring disc and a paring tube is
located inside the connection house. The pipe
has channels for incoming and outgoing
process liquid.
The paring disc and paring tube pump the
cleaned oil and water respectively out of the
bowl.
The paring tube can move radially. During
separation it surfs on the liquid surface. It is
balanced by a spring.
Under certain operating conditions, the paring
tube radial position can be locked in place by
two adjustable screws on the connection house.
The paring disc and tube are located inside and
at the top of the separator bowl.
The inlet and outlet device is held together
against the frame hood by a nut on the end of
the inlet pipe.
Height adjusting rings determine the height
position of the paring disc and paring tube
relative to the bowl.

4 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 1 SEPARATOR DESIGN

Pipe

Spring

Uncleaned oil

Cleaned oil

Water

Arm

Paring tube
Paring disc

Connection house

G0886141

1810745-02 5
1 SEPARATOR DESIGN SA 825 SEPARATION SYSTEM SERVICE MANUAL

Separator bowl
The separator bowl, with its sludge discharge
mechanism, is built-up as follows:
The bowl body and bowl hood are held together
by a lock ring (Centrilock). Inside the bowl are
the distributor and the disc stack. The disc stack
is kept compressed by the bowl hood. The
discharge slide forms a separate bottom in the
bowl body.
The upper space between the bowl hood and the
top disc forms the water paring chamber and
contains the paring tube, which pumps the
separated water out of the bowl. The oil paring
chamber, with its paring disc, is located inside
the top of the distributor. From here the cleaned
oil is pumped out of the bowl.
The sludge space is in the bowl periphery. The
bowl is kept closed by the discharge slide, which
seals against a seal ring in the bowl hood.
At fixed intervals, decided by the operator, the
discharge slide drops down to empty the bowl of
sludge.
The sludge discharge mechanism, which controls
the movement of the discharge slide, is
comprised of an operating slide and an operating
water device. Passive parts are: nozzle and valve
plugs. The operating water cover, beneath the
bowl, supplies operating water to the discharge
mechanism via the operating water ring.

6 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 1 SEPARATOR DESIGN

Water paring chamber

Bowl hood

Top disc
Oil paring chamber
Bowl body
Disc stack
Lock ring

Seal ring

Discharge
slide

Operating slide

Sludge space

Nozzle
G0886951

Holder Operating water ring

1810745-02 7
1 SEPARATOR DESIGN SA 825 SEPARATION SYSTEM SERVICE MANUAL

1.4 Sensors
The separator is equipped with a speed
sensor. As an option, an unbalance sensor
can be fitted.

Speed sensor Unbalance sensor (option)

A speed sensor indicates the speed of the separator. The For indication of any abnormal unbalance, the separator can
correct speed is needed to achieve the best separating be equipped with a sensor monitoring the radial position of
results and for reasons of safety. Refer to name plate for the bowl spindle.
speed particulars.
Cover interlocking switch (option)
When the cover is closed the interlocking circuit in the control
system is closed which makes it possible to start the
separator.

Cover interlocking switch

Unbalance sensor

Speed sensor
G0873471

8 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 1 SEPARATOR DESIGN

1.5 Separating Function

The separator separates water and solids from the uncleaned oil. Water normally leaves
the separator through the water outlet. During sludge discharge, solids (sludge) and water
are removed through the discharge ports.

1.5.1 The liquid balance in the bowl

The liquid levels in the bowl depend on many
factors (bowl geometry, liquid densities, flow
rates etc.). To get a picture of how the liquids
are distributed in the bowl, imagine that the
bowl is at standstill and turned 90° (only
influenced by gravity). The bowl can now be
compared with a settling tank:

SEPARATOR BOWL TURNED 90°

Unseparated oil

Separated oil
Water

G
R
Top disc
A Distributor
V Oil/water interface
I
T
Y Unseparated oil
Separated oil
Water

SETTLING TANK
G0886431

1810745-02 9
1 SEPARATOR DESIGN SA 825 SEPARATION SYSTEM SERVICE MANUAL

1.5.2 Liquid flow

Unseparated oil is fed into the bowl through the
inlet pipe and travels via the distributor towards
the periphery of the bowl.
When the oil reaches slots in the distributor, it
rises through the channels formed by the disc
stack, where it is evenly distributed.
The oil is continuously cleaned as it travels
towards the centre of the bowl. When the cleaned
oil leaves the disc stack, it flows through a
number of holes in the distributor and enters the
oil paring chamber. From here it is pumped by
the oil paring disc, and leaves the bowl through
the oil outlet. Separated water, sludge and solid
particles, which are heavier than the oil, are
forced towards the periphery of the bowl and
collect in the sludge space.
The space between the bowl hood and top disc, as
well as the water paring chamber, is filled with
oil, which is distributed over the entire
circumference via the grooves in the top disc.
During normal operation, the water drain valve
in the water outlet is closed.

1.5.3 Discharge of sludge and water

As the sludge space fills up and water enters the
disc stack, traces of water will escape with the
cleaned oil. The increase of water content in the
cleaned oil is the sign of reduced separation
efficiency.
This condition is monitored by the process
control system, and water is removed from the
bowl when minimal levels are recorded.
The water is removed by either of two ways:
· The water drain valve opens and the water
leaves the bowl through the water outlet.
· Through the sludge ports at sludge
discharge.
Which way is decided by the process control
system.

10 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 1 SEPARATOR DESIGN

1.5.4 ALCAPTM concept

When the sludge space is filled up and water
enters the disc stack, traces of water will escape
with the cleaned oil. The increase of water
content in the cleaned oil is the sign of reduced
separation efficiency.
This condition is monitored by the process
control system, and water is removed from the
bowl when minimal levels are recorded.

1810745-02 11
1 SEPARATOR DESIGN SA 825 SEPARATION SYSTEM SERVICE MANUAL

DISCHARGE OF WATER THROUGH WATER OUTLET

Unseparated oil

Bowl hood
Separated oil

Oil paring disc Water

Water paring tube

Water paring chamber
Oil paring chamber
Holes in distributor

Top disc

Sludge
space

Oil/water interface
Uncleaned oil

Cleaned oil

Water
G0886231

12 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2 Separator Service, Dismantling,

Assembly
2.1 Technical Data
Alfa Laval ref. 569216, rev. 2, 567322, rev. 0

NOTE

The separator is a component operating in an

integrated system including a monitoring system.
If the technical data in the system description does
not agree with the technical data in this instruction
manual, the data in the system description is the
valid one.

Product number: 881201-02-01

Separator type: S 825
Application: Cleaning of fuel and lube oil.
Technical design: Intended for marine- and
land installations.
Total discharge.
Designed in accordance with standards:

98/37/EC Directive of the European Parliament and the Council relating to

machinery.

89/336 EEC EMC and amendments related to said directive.

EN 292-2 Safety of machines. Use of the machine in applications subject to

hygienic demands requires a well adapted cleaning program.

Restrictions:
Feed temperature: 0°C to +100°C
Ambient temperature +5°C to +55°C
Discharge intervals: min. 2 minutes max. 2 hours.
Maximum allowed density of operating liquid:
1000 kg/m3.
Viscosity max. 700 cSt at 50°C.
Not to be used for liquids with flashpoint below
60°C.
Remote restart allowed under certain conditions,
see Interface description.

1810745-02 13
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

Subject Value Unit

General technical data:
Motor power 4,9 kW
Gear ratio 283 / 70 50Hz
Gear ratio 235 / 70 60Hz
Alarm levels for vibration monitor,
connection 752, 1st/2nd 0,2 / 0,3 mm
Bowl max. inner diameter 208,5 mm
Discharge interval, min./max. 2 / 120 minutes
Max. density of operating liquid, max. 1000 kg/m³
Max. density of feed/sediment 1100 / 2327 kg/m³
Feed temperature, min./max. 0 / 100 °C
Max. running time without flow,
- empty bowl 30 minutes
- filled bowl 30 minutes
Bowl body material AL 111 2377-02
Operating data:
Bowl speed, synchronous 12129/12086 r/min 50Hz/60Hz
Motor speed synchronous 3000 / 3600 r/min 50Hz/60Hz
Power consumption at start-up, max. 6,4 kW
Power consumption idling/max.
capacity: 2,6 / 6,3 kW
Starting time, min./max. 100 / 120 seconds
Stopping time min./max. 18 / 22 minutes
Sound power 9 Bel(A)
Sound pressure 76 dB(A)
Vibrations, new sep/sep in use 4 / 5,6 mm/s
Volume and capacity data:
Max. hydraulic capacity, bowl 5,5 m³/h (water at 3,5 bar)
Bowl liquid volume 1,8 litres
Fixed discharge volume 1,6 litres
Sludge volume, efficient/total 0,23 / 0,74 litres
Lubricating oil volume 1,7 litres
Weight information:
Motor drive 58 kg
Bowl 35 kg
Separator total 275 kg

14 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.2 Connection List

Alfa Laval ref. 567321 rev. 0

No. Description Requirements/limits

201 Inlet for process liquid

· Allowed temperature Min. 0 °C, max. 100 °C
· Max allowed density See ‘‘Technical Data” on page 13
· Allowed flow Max 4,5 m3/h

206 Inlet for conditioning and displacement liquid Fresh water

· Instantaneous flow 0,9 litres/minute

220 Outlet for light phase, clarified liquid

· Counter pressure 0 - 250 kPa

221 Outlet for heavy phase No counter pressure.

222 Outlet for solid phase

· Small discharge
· Large discharge Total discharge
· Discharge frequency Max 24 discharge/h.
The outlet from the cyclone must always be
arranged to prevent the cyclone from being
filled up with sludge. Solids are discharged
by gravity.

1810745-02 15
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

375 Inlet for discharge and make-up liquid

· Quality requirements See the Installation System Reference
· Max density booklet.

· Pressure Max. 1000 kg/m3

Make-up liquid Min. 150 kPa

· Flow (momentary)
· Consumption 2,8 litres/minute

· Interval 1,7 litres/hour

· Time 5 minutes

Discharge liquid 3 seconds

· Flow
· Consumption 11 litres/minute

· Time 0,55 litres/discharge

Closing liquid 3 seconds

· Flow
· Consumption 2,8 litres/minute

· Time 0,7 litres/discharge

Start up closing liquid 15 seconds

· Flow
· Time 11 litres/minute
5 seconds

462 Drain of frame top section, lower

701 Motor for separator

Allowed frequency variation: ± 5%
(momentarily during 5 seconds) ± 10%
740 Speed sensor for bowl spindle See page 21.
· Type Inductive promixly switch
· Supply voltage, nominal 8V
· With sensor activated (near metal) Less or equal to 1 mA.
· With sensor not activated (far from metal) More or equal to 3 mA.
· Number of pulses per revolution 1

752 Position transducer for bearing holder See page 22.

· Type Inductive analogue sensor
· Supply voltage 18 to 30 V DC
· Operation range (mild steel) 0,5 to 2,5 mm
· Output voltage within sensing range 4 to 20 mA
· Load resistance, RL 400 Ohm

760 Cover interlocking switch

· Type Mechanical limit switch
· Switch rating, resistive load max. 3 A (at 48 V DC)
1 A (at 220 V AC)

16 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.3 Interface Description

Alfa Laval ref. 564834 rev. 2

2.3.1 Scope
This document gives information,
requirements, and recommendations about
operational procedures and signal processing
for safe and reliable operation of the
separator. It is intended to be used for
designing auxiliary equipment and control
systems for the separator.

2.3.2 References
This Interface Description is one complementary
document to the separator. Other such
documents that contain necessary information
and are referred to here are:
· Interconnection diagram
· Connection List
· Technical Data

Standards referred to are:

· EN 418 Safety of machinery - Emergency stop
equipment, functional aspects - Principles of
design
· EN 1037 Safety of machinery - Prevention of
unexpected start-up
· EN 954-1 Safety of machinery - Safety related
parts of control systems - Part 1 General
principles for design.

1810745-02 17
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

2.3.3 Definitions
For the purpose of this document, the following
definitions apply:
· Synchronous speed: The speed the machine
will attain when it is driven by a three phase
squirrel-cage induction motor and there is no
slip in the motor and the drive system.
· Full speed: The synchronous speed minus
normal slip.

2.3.4 Goal
To eliminate situations that can cause harm, i.e.
injury, damage to health or property and
unsatisfactory process result are e.g.:

Situation Effect

Unbalance caused by uneven sediment Too high stress on bowl and bearing
accumulation in the bowl. system which might cause harm.

Too high bowl speed. Too high stress on bowl which might
cause harm.

Access to moving parts. Can cause injury to person who

accidentally touches these parts.

Insufficient cleaning of separator. Unsatisfactory product quality.

Bowl leakage. Product losses.

Information and instructions given in this

document aim at preventing these situations.
Control and supervision can be more or less
comprehensive depending on the type of used
control equipment. When a simple control unit is
used it would be impossible or too expensive to
include many of the functions specified here
while these functions could be included at nearly
no extra cost when a more advanced control unit
is used. For this reasons functions that are
indispensable or needed for safety reasons to
protect the machine and/or personnel are
denoted with shall while other functions are
denoted with should.

18 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.3.5 Description of separator

modes
For control purposes the operation of the
separator should be divided into different modes.
The normally used modes are described below
but other modes might exist.
It is assumed that:
· The separator is correctly assembled.
· All connections are made according to
Connection List, Interconnection Diagram and
Interface Description.
· The separator control system is activated.
If above conditions are not fulfilled the separator
will be in SERVICE mode.

Stand still means:

· The power to the separator motor is off
· The bowl is not rotating.

Starting means:
· The power to the separator motor is on.
· The bowl is rotating and accelerating

Running means:
· The power to the separator motor is on.
· The bowl is rotating at full speed.
· RUNNING is a collective denomination for a
number of sub modes which e.g. can be:
– STAND BY: Separator is in a waiting mode
and not producing.
– PRODUCTION: Separator is fed with
product and producing.
– CLEANING: Separator is fed with cleaning
liquids with the intention to clean the
separator.

1810745-02 19
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

Stopping means:
· The power to the separator motor is off.
· The bowl is rotating and decelerating.
· STOPPING is a collective denomination for a
number of sub modes which e.g. can be:
– NORMAL STOP: A manually or
automatically initiated stop.
– SAFETY STOP: An automatically initiated
stop at too high vibrations.
– EMERGENCY STOP: A manually initiated
stop at emergency situations. This stop will
be in effect until it is manually reset.

2.3.6 Remote start

This machine may be started from a remote
location under the following conditions;
· First start after any kind of service or manual
cleaning must be supervised locally in order
to ensure that no mistakes has been made
during assembly.
· The unbalance sensor is mandatory for
remote start.
· The installation must include equipment to
prevent unintentional start-up from remote
location when the machine is disassembled.
· The installation must include equipment to
prevent unintentional start of process flow
from remote location when the machine is not
properly connected to the piping.

2.3.7 Handling of connection

interfaces

Electrical connections
701 Separator motor.
The separator is equipped with a 3-phase DOL -
(direct on line) started motor. The separator can
also be started by a Y/D starter, but then the
time in Y-position must be maximized to 5
seconds.

20 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

There shall be an emergency stop circuit

designed according to EN 418 and a power
isolation device according to EN 1037.
There shall be a start button close to the
separator that shall be used for first start after
assembly of the separator.
There should be a counter to count number of
running hours.
There should be a current transformer to give an
analogue signal to the control unit about the
motor current.

740 Speed sensor

A proximity sensor of inductive type according to
DIN 19234 (Namur) standard is giving a number
of pulses per revolution of the bowl (see
Connection List).
Signal processing in STARTING:
· The separator should be stopped
automatically according to NORMAL STOP
procedure and an alarm should be given
when the accumulated time for acceleration is
longer than the maximum time specified in
Technical Data. An abnormal start time
indicates some malfunction of the separator
equipment and should be investigated.
· If the speed exceeds “Bowl speed,
synchronous” in Technical Data with more
than 5% the separator shall be stopped
automatically by NORMAL STOP and a high
speed alarm shall be given.
· The speed monitoring system shall be
checked continuously (e.g by checking that
pulses are coming). In case of failure
indication the separator shall be stopped
automatically by NORMAL STOP with a timer
controlled stop sequence and an alarm for
speed monitoring system failure shall be
given.
· The acceleration should be supervised to
ensure that a certain speed (e.g 250r/min.)
has been reached within a certain time (e.g 30
seconds).

1810745-02 21
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

Signal processing in RUNNING:

· If the speed exceeds “Bowl speed,
synchronous” in Technical Data with more
than 5% for a period longer than 1 minute or
momentarily during maximum 5 seconds more
than 10% the separator shall be stopped
automatically by NORMAL STOP and a high
speed alarm shall be given.
· If the speed falls more than 10% below the
synchronous speed for a period longer than 1
minute or 15% during more than 5 seconds a
low speed alarm should be given. Low speed
indicates some malfunction of the separator
equipment and shall be investigated.
· The speed monitoring system shall be
checked continuously (e.g. by checking that
pulses are coming). In case of a failure
indication an alarm for speed monitoring
system failure shall be given. If there is a risk
of too high speed the separator shall be
stopped by NORMAL STOP.
· The speed drop during DISCHARGE.
compared to the measured speed
immediately before, should be between 3-8%
which will indicate a proper discharge.
Signal processing in STOPPING:
· STAND STILL shall be indicated when no
pulses are detected within 30 seconds.
· Stopping the separator when alarm for speed
monitoring system failure is active, shall cause
a timer controlled stop. (See “Stop time” in
Technical Data.)

752 Unbalance sensor (option).

For indication of any abnormal unbalance and to
be able to perform appropriate countermeasures,
the separator has been equipped with a vibration
velocity transducer on the separator frame. The
signal from the transducer shall be monitored
and two alarm levels according to the vibration
alarm levels in Technical Data should be set.

22 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

The vibration level shall be high for 3 seconds to

generate an alarm. The first level is only used to
generate an alarm while the second level shall
stop the machine.
The vibration monitor shall include self check
function to be performed at least at initiation of
STARTING.
If vibrations exceed the second alarm level the
separator shall be stopped the quickest way
possible and it shall not been restarted until the
reasons for the unbalance have been found and
measures to remove them have been taken.
Signal processing in STARTING:
If vibrations exceed the second alarm level the
separator shall be stopped automatically by
SAFETY STOP.
If the self check system triggers, an alarm shall
be given and an automatic stop by NORMAL
STOP shall be initiated.
Signal processing in RUNNING:
· If vibrations exceed the first alarm level an
alarm should be given. Vibrations of this
magnitude will reduce the expected life time
of the bearings and should therefore be
eliminated.
· If vibrations exceed the second alarm level
the separator shall be stopped automatically
by SAFETY STOP.
· If the self check system triggers, an alarm
shall be given.
Signal processing in STOPPING:
· If the self check system triggers, an alarm
shall be given.
Signal processing in NORMAL STOP:
· If vibrations exceed the second level the
system shall turn over automatically to
SAFETY STOP.

1810745-02 23
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

760 Cover interlocking switch (option)

The separator is equipped with a interlocking
switch to detect if the cover is mounted.

Signal processing in STAND STILL:

· The circuit is closed when the cover of the
separator is mounted.
· The interlocking switch should be connected
in such a way that starting of the motor is
prevented when the separator cover is not
mounted.

Signal processing in STARTING, RUNNING

and CLEANING:
· If the circuit is broken the separator should be
stopped automatically by NORMAL STOP.
This is to minimise the risk of having access to
moving parts.

Fluid connections
Complementary information is given in the
document Connection List.
201 Inlet
Processing in STAND STILL:
· Shall be closed.
Processing in STARTING:
· Should be closed. Bowl will be open and
empty or closed and filled depending on if
start is done from STAND STILL or STOPPING.
Processing in RUNNING:
· Could be closed or open.
Processing in CLEANING:
· A sequence of cleaning liquids should be fed
to the separator. The flow rate should be as
high as possible and preferably not less than
the production flow rate.
Processing in NORMAL STOP or EMERGENCY
STOP:

24 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

· Could be closed or open but the bowl should

be filled unless the stop is initiated in
STARTING.
Processing in SAFETY STOP:
· Could be closed or open but the bowl shall be
filled unless the stop is initiated in STARTING.
206 Inlet for conditioning and displacement
liquid
· According to process

220, 221 and 222 Outlets

Processing in STAND STILL:
· Could be closed or open.

Processing in other modes:

· Shall be open.

375 Inlet for discharge and make-up liquid

Processing in all modes:
· It is recommendable to supervise the supply
pressure. If pressure is too low (see
Connection List), start should be interlocked
and if it happens in PRODUCTION or
CLEANING turn over to STAND BY should
take place.
Signal processing in STARTING:
· Below 85 % of synchronous bowl speed no
water supply may be made.
· When coming from PRODUCTION a
discharge shall be initiated to remove
sediments from bowl to avoid problems due to
solidification, see Connection List.
Signal processing in PRODUCTION:
· Automatic discharges shall be initiated by
timer or ALCAP system.
Signal processing in CLEANING:
· Automatic discharges shall be initiated by
timer or CIP-control system.
Signal processing in NORMAL STOP:

1810745-02 25
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

· Discharges should not be made.

Signal processing in SAFETY STOP and
EMERGENCY STOP:
· Discharges should not be made.

26 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.3.8 Interconnection diagram

Alfa Laval ref. 561786 rev.4

Interlocking switch (frame top part)

Unbalance sensor (position trans.

for bearing holder).

Speed sensor (bowl speed).

Junction box

Wiring of connector “X”: Wire colour codes:

RD=A BK=Black
BU=B BN=Brown
GN=C BU=Blue
YW=D RD=Red
WT=E GN=Green
BK=F PU=Purple
BN=G YW=Yellow
PU=H WT=White
G0867541

Items showed in this document are not included in all

separators. See product specification.

Demand specification wire

Approval: UL 1007/1569
CSA TR-64
Area acc. to AWG 18

1810745-02 27
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

2.3.9 Electric motor

Alfa Laval ref. 565595 rev. 0

Knockout openings for cable glands

on both sides.
Casted lifting lugs
External depth 20
earthing bolt

The rotor balanced with

half key. Max. vibration

G0938221
velocity 1,8 mm/s (rms)
acc. to IEC 34-14 Metal fan cover Note: The motor
bearings have
permanent
lubrication

Manufacturer ABB Motors

Manuf. drawing Cat. BA/Marine mot./GB 98-05

Standards IEC 34-series, 72, 79 and 85

Size IEC 112MB

Type M2AA 112 MB

Weight 33 kg

Poles 2
Insulation class F

Bearings D-end 6206-2Z/C3

N-end 6206-2Z/C3

Method of cooling IC 411 (IEC 34-6)

Spec. Totally enclosed three-phase

motor for marine service 2)
Motor with feet and small flange.

28 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

Type of mounting Degree of

protection
IEC 34-7 IEC 34-5

IM 2101 IP 55

IM 2111 IP 55

IM 2131 IP 55

Article Output Speed Freq Voltage Current A Pow.fac | st / |1) Note

No. kW rpm Hz V cos j

565595-19 5,7 3445 60 200D 20 0,93 7,7

565595-18 5,7 3445 60 230D 17,4 0,93 7,7

565595-17 5,7 3445 60 220D 18,2 0,93 7,7

565595-16 5,7 3445 60 690Y 5,8 0,93 7,7

565595-15 5,7 3445 60 380Y 10,5 0,93 7,7 -

565595-14 5,7 3445 60 575Y 7,0 0,93 7,7

565595-13 5,7 3445 60 480Y 8,3 0,93 7,7 CSA- plated

565595-12 5,7 3445 60 460Y 8,7 0,93 7,7 -

565595-11 5,7 3445 60 440Y 9,1 0,93 7,7 -

565595-10 4,9 2855 50 200D 17,5 0,94 7,6 -

565595-9 4,9 2855 50 230D 15,2 0,94 7,6 -

565595-8 4,9 2855 50 220 D 15,9 0,94 7,6 -

565595-7 4,9 2855 50 690Y 5,1 0,94 7,6 -

565595-6 4,9 2855 50 660Y 5,3 0,94 7,6 -

565595-5 4,9 2855 50 500Y 7,0 0,94 7,6 -

565595-4 4,9 2855 50 440Y 7,9 0,94 7,6 -

1810745-02 29
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

565595-3 4,9 2855 50 415Y 8,4 0,94 7,6 -

565595-2 4,9 2855 50 400Y 8,7 0,94 7,6 -

565595-1 4,9 2855 50 380Y 9,2 0,94 7,6 -

1) lst /l=starting current /rated current at direction line starting.

2) The motors can be designed to fulfil requirements of following Classification
Societies (Essential Service, if required).
Lloyds Register of Shipping (LRS)
Det Norske Veritas (DnV)
Germanischer Lloyd (GL)
Bureau Veritas (BV)
American Bureau of Shipping (ABS)
Registro Italiano Navale (RINA)
Nippon Kaiyi Kyokai (NK)
Korean Register of Shipping (KR)
Polski Rejester Statkow (PRS)
China Classification Societies (ZC)
Indian Register of Shipping (IRS)
Maritime Register of Shipping (IRS)

Required classification society must always be specified when ordering. Factory

test certificate to be enclosed at the delivery.
Rated output (kW) valid for temp-rise max. 90 °C.
The motors can be provided with space heaters for 110 V or 220 V, 25 W as option.

30 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.4 Nomogram paring tube

Alfa Laval ref. 566571, rev. 0

Calculated level ring ø 61

G0938021

A Density ratio

1810745-02 31
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

G0938121

A Paring radius
B Position of adjusting screw

32 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.5 Maintenance

2.5.1 Periodic Maintenance

Periodic (preventive) maintenance reduces
the risk of unexpected stoppages and
breakdowns. Follow the maintenance log in
this chapter in order to facilitate the periodic
maintenance.

2.5.2 Maintenance intervals

The following directions for periodic
maintenance give a brief description of parts to
be cleaned, checked and renewed at different
maintenance intervals.
The maintenance log for each maintenance
interval on page 37 gives a detailed list of actions
to be performed.

Inspection i i
An Inspection consists of an overhaul of the
separator bowl, inlet/outlet and operating water
device every 6 months or 4000 operating hours.
Seals in bowl and gaskets in inlet/outlet device
are renewed.

Overhaul o
An Overhaul consists of an overhaul of the
complete separator (including separator bowl,
inlet/outlet and operating device) every 18
months or 12000 operating hours. Seals,
bearings, friction blocks and flat belt in the
separator are renewed.

Oil change
The oil should be changed every 4000 hours, or at
least once every year if the total number of
operating hours is less than 4000 hours/year.

1810745-02 33
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

2.5.3 Maintenance procedures

At each Inspection and/or Overhaul, take a copy
of the maintenance log and use it to make notes
during the service.
An inspection and overhaul should be carried out
as follows:
1 Dismantle the parts as described in 2.7
Dismantling, page 39.
Place the separator parts on clean, soft
surfaces such as pallets.
2 Inspect and clean the dismantled separator
parts according to the maintenance log and
description in 2.8 Actions Before Assembly,
page 71.
3 Fit all the parts delivered in the service kit
while assembling the separator as described
in chapter 2.9 Assembly, page 78.
4 When the separator is assembled, make final
checks described in 2.10 Actions After
Assembly, page 113.

R
! DANGE

Disintegration Hazards
Separator parts that are either missing, worn
beyond their safe limits or incorrectly assembled,
may cause severe damage or fatal injury.

ON
CAUTI
!

Burn and Corrode Hazards

Escaping hot and/or corroding process material,
which can be hazardous, may still remain in the
separator after stop.

The use of service symbols in the

dismantling/assembly instructions
Parts that have to be renewed from the service
kits (see below) are marked i i and/or o in
the assembly instructions.

34 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

Example:
a Fit the O-ring ii .

When dismantling and assembling between the

service periods, some procedures do not have to
be carried out. These procedures are marked
i i and/or o .
Example:
5 Renew the valve plugs on the operating slide
ii .
All symbols used in the instructions refer to
activities mentioned in the maintenance logs.

2.5.4 Tightening of screws

Tightening all screws with the correct torque
value is important.
These figures apply unless otherwise stated:

Torque

Metric Stainless steel Carbon steel

thread
Nm kpm Ib.ft Nm kpm Ib.ft

M6 7 0,7 5 8 0,8 5,9

M8 17 1,7 13 20 2 14,7

M10 33 3,4 24 39 3,9 28,7

M12 57 5,8 42 68 6,9 50

M16 140 14 100 155 15,8 114

M20 270 28 200 325 33 239

M24 470 48 340 570 58 420

The figures apply to lubricated screws tightened

with a torque wrench.

2.5.5 Service kits

Special service kits are available for Inspection
and Overhaul.

1810745-02 35
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

For other services, a Support kit is available.

Spare parts not included in the Support kit have
to be ordered separately.
Note that the parts for Inspection are included
in the Overhaul kit.
The contents of the kits are described in the
Spare Parts Catalogue.

NOTE

Always use Alfa Laval genuine parts as otherwise

the warranty may become invalid.
Alfa Laval takes no responsibility for the safe
operation of the equipment if non-genuine spare
parts are used.

ING
WARN
!

Disintegration hazards
Use of imitation spare parts may cause severe
damage.

2.5.6 Cleaning
CIP (Cleaning In Place)
To prolong the intervals between manual
cleaning of the separator the use of CIP together
with repeated discharges can be used.
Some CIP liquids can be corrosive to brass- and
aluminium alloy parts which are included in the
separator.

N
CAUTIO
!

Use only Alfa Laval recommended CIP liquids.

36 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.6 Maintenance Log

Name of ship/plant: Local identification:

Separator: SA 825 Separation System Manufacture No./Year:

Total running hours: Product No.: 881201-02-01

Date: Inspection Signature:

Overhaul

Check

Part i o Action Page Note

Frame hood
- All parts x x Clean 71
- All parts x x Check for corrosion 72
- All parts x x Check for cracks 73
- Connecting housing x x Check for erosion damages 74
- Frame hood x x Renew O-ring 107
x Control measure of paring disc height 108
x Check height adjusting rings 108
Bowl
- All parts x x Clean 71
- All parts x x Check for corrosion 72
- All parts x x Check for cracks 73
- All parts x x Check for erosion damages 74
- Bowl body x x Check for impact marks and corrosion 94
x x Renew rectangular ring 95
x x Renew O-rings 96, 99
- Operating slide x x Renew rectangular ring 95
x x Renew valve plugs 94
- Discharge slide x x Renew rectangular ring 99
- In and outlet pipe x x Renew O-rings 102
- Paring tube x x Renew O-ring 102
- Bowl hood x x Renew seal ring 104
x x Renew O-ring 104
Frame
- Frame feet Renew frame feet (including washers 76 Has to be ordered
and screws) separately
- Drain and oil filling holes x x Renew washers 93
- Oil pin x x Renew O-ring 93

1810745-02 37
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

Inspection

Overhaul

Check
Part i o Action Page Note
Driving device
- All parts x Clean 71
- All parts x Check for corrosion 72
- All parts x Check for cracks 73
- Bottom bearing housing x Renew O-ring 82
- Labyrinth ring holder x Renew labyrinth ring 83
x Renew O-ring 83
- Top bearing housing x Renew springs 85
- Flat belt x Renew flat belt 89
- Bowl spindle x Pre-lubricate and renew ball bearing 84
x Pre-lubricate and renew self-aligning
roller bearing 86
x Lubricate the spindle
x Measure the radial wobble 92
- Neck bearing cover x Renew O-ring 91
- Deflector ring x Renew O-ring 91
- Water inlet pipe x Renew O-ring 92
- Operating water cover x Renew seal ring and O-ring 92
- Fan x Renew the O-ring 88
Coupling
- All parts x Clean 71
- All parts x Check for corrosion 72
- All parts x Check for cracks 73
- Coupling hub x Renew single row ball bearings
- Friction blocks x Renew friction pads (if they are worn) 78
or clean the pads if they are oily
Electrical motor
- Electrical motor x Lubricate if nipples are fitted. See sign ---
on motor
Signs and labels on separator
- Machine plate x Check attachment and legibility 113
- Power supply frequency x Check attachment and legibility 113
- Lifting instructions x Check attachment and legibility 113
- Safety labels x Check attachment and legibility 113
- Name plate x Check attachment and legibility 113
- Representative label x Check attachment and legibility 113

38 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.7 Dismantling

2.7.1 Introduction
The frame hood and heavy bowl parts must
be lifted by means of a hoist. Position the
hoist exactly above the bowl centre. Use a
lifting sling and lifting hooks with safety
catches.

The parts must be handled carefully. Don’t

place parts directly on the floor, but on a
clean rubber mat, fibreboard or a suitable
pallet.

NOTE

For safety reasons, it is essential that all personnel

who work with the separator read this manual
thoroughly and completely.
Do not allow personnel to clean, assemble, operate
or maintain the separator until they have read and
fully understood this manual.
Ensure that all personnel who operate and service
the separator are well-trained and knowledgeable
concerning the separator and the work to be carried
out.

2.7.2 Tools
Special tools from the tool kit must be used for
dismantling and assembly, as well as Standard
tools (not included). The special tools are
specified in the Spare Parts Catalogue and are
illustrated at the beginning of each dismantling
section.

ING
WARN
!

Entrapment hazard
To avoid accidental start, switch off and lock-out
power supply before starting any dismantling work.

Make sure that machine has come to a complete

standstill before starting any dismantling work
(takes about 22 minutes from switch off).

1810745-02 39
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

Standard Tools

3 4

1 2 6

7 12
9 11
10
8
13

14

G0911641
1 Screwdriver
2 Torque wrench (capacity 0-200 Nm)
3 Drift ( Ø 4 mm)
4 Dial indicator with magnetic base
5 Spanner for clutch
6 Heating equipment for bearings
7 Sliding calliper
8 Hammers (standard and soft-faced)
9 Pliers for internal snap rings
10 Pliers for external snap rings
11 T-handle with extension rod, sockets
(13, 16, 17, 18, 19, 27, 30 mm)
12 Spanners (various sizes)
13 Adjustable spanner
14 Shackle

40 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.7.3 Frame hood

Lock nut
Washer

Connecting
housing

Spring

Arm

G0863331
Screws

G0860531
1

1 Hook spanner (lock nut)

Frame hood

ING
WARN O-ring
!
Height adjusting
rings
Entrapment hazard
To avoid accidental start, switch off and lock-out the Support ring

G0863451
power supply before starting any dismantling work.

Make sure that machine has come to a complete

standstill before starting any dismantling work
(after about 55 minutes from switch off).

1 Removing the connecting housing.

a Remove the lock nut using the

hook spanner.
NOTE

ING Remove connections before

WARN starting dismantling.
!

The nut must not be b Press the pipe down to loosen

removed before the the connecting housing.
separator has stopped.

Remove the washer

c Remove the connecting housing
NOTE
.

Right hand thread.

G0863531

1810745-02 41
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

2 Removing the spring and arm.

a Remove the spring from

the pin on the hood.

b Remove the arm

together with the
spring.

c Turn the paring tube so that the frame hood can be

removed upwards.

NOTE

To avoid the paring tube from being damaged

and preventing the inlet pipe from sticking to
the frame hood when lifting the hood, always
turn the paring tube towards the pipe before
lifting.

G0863661
Paring tube

3 Removing the frame hood.

a Remove the screws holding

the frame hood. c Lift off the frame
hood.

NOTE
b Loosen the hood
Do not place
by bending with
the hood
a screwdriver in upside down.
all grooves in the
hood.
G0863671

42 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.7.4 Bowl Lock ring

Bowl hood

Seal ring

O-ring

Top disc

O-rings

G0861621
Inlet and outlet
pipe
Paring tube

Axial support.
1
Splash sealing

Bowl disc
(without caulks)
Bowl discs

Distributor

Cap nut
6
Nut
4
Discharge slide
3 7
Rectangular ring
O-ring
5

8 Bowl body

10 Rectangular ring
G0860571

11
O-ring

Valve plugs
1 Compressing tool (lock ring)
2 Lifting eyes Operating slide
3 Bowl hood puller
4 Spanner for nut (nut/discharge slide) Rectangular ring
5 Puller (discharge slide)
O-ring
6 Lifting tool (distributor, spindle)
7 Puller (Bowl body) Holder
8 Screw (lock ring) (M5) Nozzle
Operating water ring
G08626B1

9 Hexagon head key

10 Chisel (seal ring)
11 Pin (distributor/lifting tool) Ring

1810745-02 43
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

1 Removing the lock ring.

a Fit the compressing tool.

c Compress the disc stack by
alternately tightening the
b Screw in the screws to
screws on the compressing
stop.
tool a maximum of 40 Nm at a
time.
NOTE

Be sure not to
cover the threaded
holes.

d Fit the dismantling screws

to the bowl body and
press out the lock ring by
tightening the screws
successively going
counter-clockwise. Start
with the screw nearest the
lock ring end (the one
without the guide pin).
The lock ring can be
removed when it has
passed the edge of the
groove.

e Remove the lock ring

from the groove.

f Remove the
dismantling screws.
G0862751

44 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2 Removing the bowl hood.

a Loosen the screws on the b Fit the puller.

compressing tool.
Remove the tool.
Remove the lock ring.

c Fit the compressing tool.

Loosen the screws (de-
compress) on the
compressing tool. Pull the
bowl hood off by continuing to
unscrew the screws.

d Remove the
compressing tool
and attach the
lifting eyes to the
puller and lift off
the bowl hood.

ING
WARN
!

Crush hazard
The top disc can adhere to the bowl
hood when lifting. Be careful not to
accidentally drop it.
G0862861

1810745-02 45
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

3 Removing the seal ring.

a Place the bowl hood on a support

and tap out a piece of the seal ring
using a drift in the holes.
b Turn the bowl hood upside down
and remove the seal ring by
carefully knock pieces of the seal
ring out of the groove, using the
special tool: chisel.

NOTE

It is very important not to

Seal ring damage the bottom of the
groove!

ING
WARN
!

Risk for eye injury from flying seal ring parts

The seal ring breaks when removed from the bowl
hood.

G0862441
4 Removing the inlet/outlet pipe and top disc.

a Lift out the in- and outlet pipe together with the top disc.

ING
WARN
!

Crush hazard
The distributor and disc stack can adhere to the
top disc. Separate them from the top disc so that
they do not accidentally drop.
G0862951

46 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

5 Removing the paring tube.

a Remove the top disc from

the inlet and outlet pipe.

NOTE

To avoid damaging the paring

tube, turn it towards the
centre of the pipe.

b Remove the splash sealing.

c Remove the screws

and the axial support

d Lift up and remove the

paring tube.

Turn the paring tube

upwards.
NOTE

If the paring tube sticks, use a drift

to carefully tap it out from the pipe.
Be careful not to damage the
paring tube.
G0863041

1810745-02 47
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

6 Removing the disc stack and distributor.

c Carefully lift off the

a Assemble the lifting tool with the pin. disc stack assembly.

b Fit the assembled tool into the

distributor and ease off the disc stack.

ON
CAUTI
!

Cut hazard
Sharp edges on the separator
discs may cause cuts

G0863161
7 Removing the nut

a To prevent the bowl body from rotating

when removing the nut;
Fit the compression tool to the bowl
b Use the spanner body and fit a screw together with a
for nut to remove socket into the frame, as shown in the
the nut. illustration.

Nut

Compressing tool

Screw

Socket (or similar)

G0923831

48 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

8 Removing the discharge slide.

a Fit the lifting tool by

pressing the puller rods
towards each other and
position them into the
two slots on the bowl b Ease off the discharge slide
bottom. by turning the central screw.
Slide metal ring down
over bowl nave.

NOTE

If discharge slide is
difficult to remove,
tap lightly on outside
edge with a soft
faced hammer.

Ring on tool
Puller rod

Discharge slide

Bowl body

c Lift out the discharge slide.

ING
WARN
!

Crush hazard
The ring on the lifting tool must be pushed
down against the discharge slide, otherwise the
discharge slide may come loose from the tool.
G0863251

1810745-02 49
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

9 Removing the cap nut.

a Remove the cap nut

NOTE

Left-hand thread!

b Remove the compressing tool.

G0860651
10 Removing the bowl body

a Fit the lifting tool to the bowl body.

b Raise the bowl body off the spindle taper

by turning the lifting eye clock-wise.

c Lift off the bowl body

G0860731

50 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

11 Turn the bowl body upside down.

ING
WARN
!

Crush hazard

G0860821
Support the bowl body when turning to prevent it from rolling.

12 Removing the holder.

a Remove the screws.

b Lift off the holder.

NOTE

If the ring sticks, use two M10

screws in threaded holes to raise
the operating slide holder up and
away from the bowl body.
G0860921

1810745-02 51
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

13 Removing the operating slide.

a Lift off the operating slide.

NOTE

If the ring sticks, use two M10 screws in

threaded holes to raise the operating
slide holder up and away from the bowl
body.

G0861021
14 Removing the operating water ring.
a Loosen and remove the screws .

b Lift off the ring.

NOTE

If the ring sticks, use two M8

screws in threaded holes to raise
the operating slide holder up and
NOTE
away from the bowl body.
The discoloration on the ring is oxide
protection. Do not clean with abrasives.
G0861121

52 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.7.5 Driving device 1 3 4 5

G0857971
G0857821
7

1 Puller (spindle pulley, 4 Lifting tool

ball bearing). (spindle assembly)
2 Tool (bearing housing). 5 Drift (bottom bearing).
3 Cover puller 6 Sleeve (ball bearing in
(neck bearing cover). top bearing seat
7 Pin spanner (oil fan).

Seal ring
Air deflector
Operating water cover

O-ring
O-rings Spindle pulley
Deflector ring

Seal ring
Neck bearing cover Belt

O-ring

O-ring
Self-aligning roller
Fan bearing
Lubrication oil orifice
Snap ring
O-ring
Oil pump
Bowl spindle

Ball bearing Labyrinth ring

Top bearing seat Wing insert

Springs
O-ring
Top bearing housing Bottom bearing
holder
Composite springs Screw

O-ring
Plugs
G0858071

Strainer

1810745-02 53
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

1 Removing the clutch cover.

a Remove the screws.

b Remove the clutch cover.

G0858131
2 Empty the oil sump.

Unscrew the oil plug and

empty the oil sump.
G0868571

54 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

3 Loosen the flat belt, by tilting the motor.

a Loosen, but do not remove, the screws holding

the motor. Start with the two screws at the bottom. Motor
Do not loosen more than shown in the illustration.
Separator frame
Nut

Screw

b Loosen the two upper screws a little bit more so

that the motor can be tilted. Do not loosen more
than shown in the illustration.

ING
WARN
!

Crush hazard
c Remove the flat belt from the motor pulley. The motor will come off if the screws are

G 0 8 5 8 8 A1
unscrewed.

1810745-02 55
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

4 Removing the operating water cover.

a Remove the screws.

b Lift off the operating water cover.

NOTE

If the cover sticks, fit two M10

screws to the threaded holes
and tighten.

G0858931
5 Removing the neck bearing cover and deflector ring.

d Lift off the neck bearing cover

together with the deflector ring.

a Attach the tools.

b Fasten the tool to

c Ease off the the cover.
cover by
tightening
the screw.

Cover
G0859051

Frame

56 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

6 Prepare for removal of spindle assembly.

NOTE

a To facilitate later removal of

plugs, loosen (do not remove)
the plugs on the bearing
housing.

b Remove the screws

NOTE

If the cover sticks, fit two M10

screws to the threaded holes
and tighten.

G0859151

1810745-02 57
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

7 Lifting the spindle assembly from the frame.

a Fit the lifting tool to the spindle end.

b Slowly raise and lift out the spindle

assembly.

ING
WARN
!

Crush hazard
Do not rotate the spindle assembly
during lifting. The spindle assembly
may otherwise come loose from the
lifting tool.

G0907831

58 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

8 Place the spindle assembly upside down on a support.

Make a support

~185 mm

~120 mm
~6,5 mm
free space

G0859211
9 Removing the air deflector.

Remove the screws and the air

deflector.

G0859221

1810745-02 59
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

10 Removing the fan.

a Turn the spindle assembly the right way up.

b Place a spanner (or similar) on

the spindle pulley key-grip, as
holder-up.
c Fit the pin spanner and
remove the fan.

NOTE
Key-grip
Left-hand thread!

G0923921
11 Removing the bottom bearing assembly.
a Turn the spindle assembly up-side down and
Puller tool
remove the oil pump by using spanners.

b Pull off the belt pulley and the

self-aligning roller bearing using
the puller tool.

NOTE

Always discard a used

bearing.

Lubrication oil orifice c Cover the the oil orifice and blow compressed
air through the bottom hole of the oil pump and
slowly ease out the lubrication oil orifice.
G0865981

Compressed air

60 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

12 Removing the top bearing housing.

a Turn the spindle
Composite b Remove the plugs
assembly over.
springs and the composite
springs.

c Carefully remove the spindle

from the top bearing seat.
Plug
NOTE

Be careful not to damage

d Collect the
the vibration indicator.
axial springs.

G0858221

1810745-02 61
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

13 Removing the ball bearing.

a Remove the snap ring.

ING
WARN
!

Risk for eye injury from flying snap ring

Use the correct pliers for dismantling of snap ring to
avoid accidental release.

b Fit the cap nut on the spindle to

protect the threads.

c Use the puller tool to remove the

top bearing seat from the spindle.

NOTE

Do not damage threads on

spindle. NOTE

Take care not to damage the

vibration indicator when
separating the top bearing
seat from the spindle.

Vibration indicator

Piece of wood to
protect the spindle
threads.

NOTE

Always discard
d Place the top bearing seat on a support to used bearings.
protect the vibration indicator.
Remove the bearing. Use a drift in the two
holes.
G0858331

62 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

14 Removing the labyrinth ring.

a Remove the ring using a

screwdriver.

NOTE

Be careful not do damage the groove.

G08586C1

1810745-02 63
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

15 Removing the bottom bearing holder.

a Fit the tool into the bottom bearing holder and attach the
socket, extension rod and T-handle.

T-handle

Extension rod

Socket

Tool

b Loosen the bottom bearing

holder by turning it counter
clockwise.
Remove it by hand.

c Remove the strainer.

G08586D1

64 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.7.6 Centrifugal clutch

Snap rings

Ball bearings
Spacing ring

Belt pulley

G0864711
Coupling
hub
ING
WARN
!

Parallel pin
Entrapment hazard
To avoid accidental start, switch off and lock-out
power supply before starting any dismantling work.
Friction blocks
(3=60 Hz)
Make sure that machine has come to a complete
standstill before starting any dismantling work Cover
(takes about 22 minutes from switch off).
Snap ring

G0865141
NOTE

50 Hz = 5 Friction blocks
60 Hz = 3 Friction blocks

The illustration shows 50 Hz

2
G0865021

1 Mounting /dismantling tool (centrifugal clutch).

2 Mounting /dismantling tool (ball bearing).

1810745-02 65
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

1 Removing the clutch cover.

a Remove the screws.

b Remove the clutch cover.

G0858131
2 Loosen the flat belt, by tilting the motor.

a Loosen, but do not remove, the screws holding

the motor. Start with the two screws at the bottom. Motor
Do not loosen more than shown in the illustration.
Separator frame
Nut

Screw

b Loosen the two upper screws a little bit more so

that the motor can be tilted. Do not loosen more
than shown in the illustration.

ING
WARN
!

Crush hazard
c Remove the flat belt from the motor pulley. The motor will come off if the screws are
G08588A1

unscrewed.

66 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

3 Removing the motor.

a Disconnect the electrical cables.

ING
WARN
!

Electrical hazard
If the cables are not disconnected during lifting procedures,
they may become damaged.

b Fit a sling to the c Tense the lifting sling to support the motor and
motor using a remove the screws. Lift the motor while supported.
shackle on the upper
part.
ING
Weight of motor with WARN
coupling: approx. !
60 kg.
Crush hazard
If not supported, the motor with coupling
will drop when removing the screws.

G0864641
d Lower the motor onto a suitable pallet.

4 Removing the friction blocks.

a Remove the snap ring, cover

and friction blocks.

Friction blocks
(3=60 Hz)

Cover

Snap ring

NOTE

50 Hz = 5 Friction blocks
60 Hz = 3 Friction blocks
G0865231

1810745-02 67
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

5 Checking the condition of the friction blocks o .

If the blocks are worn:

Fit new friction blocks.

NOTE

Replace all blocks, even if only one is

worn.

a Clean the pins of coupling hub and apply a thin

film of lubricating paste to the pins.

NOTE

Make sure that there is no oil on the pads.

b If only friction block service is to be done,

proceed to ‘‘Assembly of friction blocks” on page
80.

G0865331

68 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

Complete dismantling of centrifugal clutch

6 Removing the coupling from the motor.

a Remove the screw, spring washer and washer.

Washer

Spring washer

Screw

NOTE

Use a spanner on the coupling

hub to prevent rotation during
dismantling.

b Check that the brass plug is mounted

Flat areas for spanner. on the puller tool.
Fit the tool to the friction clutch.

c Ease off the friction coupling.

ING
WARN
!

Crush hazard
The centrifugal clutch is heavy and
can fall, causing injury, when
loosened from the motor shaft.
Puller tool

Flat areas for spanner.

G0865471

1810745-02 69
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

7 Dismantling of the coupling assembly.

a Remove the snap rings.

b Drive out the coupling hub.

Wooden support

Support

c Turn the coupling the other way round and

drive out the ball bearings using the
mounting tool.

NOTE

Always discard used bearings.

G0865511

70 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.8 Actions Before

Assembly

2.8.1 Cleaning i o
Clean the separator parts according to the
diagram below. Afterwards, protect all cleaned
carbon steel parts against corrosion by oiling.

Part Procedure Cleaning agents

Frame and The external cleaning of the frame and motor should be Water and de-greasing agent.
motor restricted to brushing, sponging or wiping while the motor is
running or still is hot.

ING
WARN
!

Electrical hazard
Never wash down a separator with a direct water
stream.
Never play a water jet on the motor. Totally
enclosed motors can be damaged by direct hosing
to the same extent as open motors, resulting in
short-circuit and internal corrosion.

Bowl Cleaning of bowl discs A chemical cleaning agent must

Inlet/ outlet Handle the bowl discs carefully in order to avoid damage to dissolve the deposits quickly without
the surfaces during cleaning attacking the material of the separator
parts.
1 Remove the bowl discs from the distributor and place them
individually in the cleaning agent. Fuel oil sludge mainly consists of
complex organic substances such as
2 Allow the discs to remain in the cleaning agent until the asphaltenes. The most important
deposits have been dissolved. This will normally take property of a cleaning liquid for the
between two and four hours. removal of fuel oil sludge is the ability to
3 Lastly, clean the discs with a soft brush. dissolve these asphaltenes.

ON
Cleaning of holder for operating slide, operating water CAUTI
ring and operating slide with nozzle. !

Use 10% acetic acid solution to dissolve lime deposits. The

acid should be heated to 80 °C. Cut hazard
Clean the nozzle on the operating slide using a soft iron wire Sharp edges on the separator
discs may cause cuts.
or a similar object.

Driving device Use a sponge or a soft brush. White spirit, cleaning-grade kerosene
or diesel oil.

Centrifugal Use a sponge or a soft brush. White spirit, cleaning-grade kerosene

clutch or diesel oil.

Belt pulley Use a a steel brush. Solvent

1810745-02 71
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

2.8.2 Inspection for corrosion i

o
Inspect the separator parts for corrosion.
Evidence of corrosion attacks should be looked
for and rectified each time the separator is
dismantled.

Max. 0,2 mm

! D
ANGER

G0205241
Disintegration hazards
Always contact your Alfa Laval representative if you
suspect that the depth of the corrosion damage
exceeds 0,2 mm for bowl body and bowl hood (0,5
for other parts) or if cracks have been found. Do not
continue to use the separator until it has been
inspected and given clearance for operation by Alfa
Laval.

Material Type of corrosive Appearance Measure

environment

Non-stainless steel Water or dampness Rust If damage exceeds 0,5 mm, contact
and cast iron parts Alfa Laval.

Stainless steel Chlorides or acidic Acidic solutions cause general Polish dark-coloured spots and
solutions corrosion. other corrosion marks with a fine
Chloride corrosion begins as small grain emery cloth. This may prevent
dark spots that can be difficult to further damage.
detect, and goes on to local damage If damage exceeds 0,5 mm (0,2 mm
such as pitting, grooves or cracks. for bowl body and bowl hood)
contact Alfa Laval.

Other metal parts “Aggressive” Possible corrosion damage can be If damage exceeds 0,5 mm, contact
environment in the form of pits and/or cracks. Alfa Laval.

R
! DANGE

Disintegration hazard
Pits and spots forming a line may indicate cracks
beneath the surface.
All forms of cracks are a potential danger and are
totally unacceptable.
Replace any part where corrosion can be
suspected of affecting its strength or function.

72 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.8.3 Inspection for cracks i o

Check the separator parts for cracks. It is
particularly important to inspect for cracks in
rotating parts, and especially the pillars between
the sludge ports in the bowl wall.

R
! DANGE

Disintegration hazard
All forms of cracks are potentially dangerous as they
reduce the strength and functional ability of
components.
Always replace a part if cracks are present.

Cracks can occur from cyclic material stresses

and corrosion. Keeping the separator and its
parts clean and free from deposits will help to
prevent corrosion attacks.

R
! DANGE

Disintegration hazards
Always contact your Alfa Laval representative if you
suspect that the depth of the damage exceeds 0,2
mm for bowl body and bowl hood (0,5 for other
parts).
Do not continue to use the separator until it has
been inspected and given clearance for operation by
Alfa Laval.

1810745-02 73
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

2.8.4 Inspection for erosion i o

Erosion may occur when particles suspended
in the process liquid slide along or strike
against a surface.

Erosion is characterised by:

Surfaces particularly subjected to erosion are:
1 Burnished traces in the
material.
2 Dents and pits having a
granular and shiny surface.

The sealing edge of the

discharge slide.
Paring disc and paring tube

Lock ring
Bowl body and holder.

Pillars between the

Holder and operating slide. sludge ports in the
bowl wall

The sealing edge of the discharge

slide for the seal ring in the bowl
hood
The underside of the distributor in the vicinity of the

G0911831
distribution holes and wings

1 Inspect the bowl and inlet/outlet parts for

erosion damages.

NOTE

Always contact your Alfa Laval representative if you

suspect that the depth of the damage exceeds 0,2
mm for bowl body and bowl hood (0,5 for other
parts). Do not continue to use the separator until it
has been inspected and cleared for operation by
Alfa Laval.

74 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2 Replace parts if erosion is suspected.

R
! DANGE

Disintegration hazard
Erosion damage weakens parts by reducing the
thickness of the material.
Pay special attention to the pillars between the
sludge ports in the bowl wall.
Replace parts if erosion is suspected of affecting
strength or function.

1810745-02 75
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

2.8.5 Exchange of frame feet

The frame feet have to be changed
occasionally due to rubber deterioration from
age.

When replacing the frame feet, the separator

must be lifted. Follow 2.12.1 Lifting the
separator, page 121.

NOTE

Discard the old frame feet, screws and washers.

a Loosen the bolts and prepare to remove

the separator frame

b Lift the separator. See ‘‘Lifting the separator” on

page 121

c Remove the existing frame feet.

d Fit the new feet, screws and washers. Tightening

torque: 160 Nm.

e Place the separator in its original position and

fasten the mounting bolts.
G0874421

76 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.8.6 Lubrication of bowl parts

a Apply Molykote 1000, or equivalent lubrication, on the

following contact surfaces. Also apply D321 on the
operating slide and the bowl body guide pin.

Nut

Discharge slide

Bowl body
(also apply D321 on guide pin)

Operating slide
(also apply D321)

Holder

Operating water ring

G0911741

1810745-02 77
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

2.9 Assembly

2.9.1 Centrifugal clutch

1 Assembly of the coupling.

a Slip the belt pulley over the coupling hub and place them on a firm and level
foundation.

ING
WARN
!

Disintegration Hazard
If the belt pulley must be renewed, check that the new pulley has the
correct diameter. An incorrect pulley will cause the separator bowl to
run at either an excessive or insufficient speed.
d=283 mm 50 Hz
d=235 mm 60 Hz NOTE

Remove rust from the

belt pulley using a steel
brush.

b Apply a thin film of oil onto the

external and internal surfaces of the
ball bearings o .

Mounting tool

c Press the ball bearings down one at a time into the coupling
hub, preferably using a hydraulic press. Place the spacing
ring between them.

NOTE

Never re-fit used ball bearings.

The ball bearings must not be heated as they are
packed with grease and sealed with plastic
membranes.

d Fit the snap rings.

G0865621

78 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2 Fitting the coupling to the motor.

a Clean the motor shaft and apply a

thin oil film.

NOTE

Make sure that the key is in place on b Apply lubricating paste to the tool
the motor shaft. threads (keep lubricated).

c Remove the brass plug.

d Fasten the sleeve of the tool to the

motor shaft with the same screw that
normally holds the centrifugal clutch
to the motor.

e Use a spanner to turn the nut on the

tool. This will press the centrifugal
clutch on to the shaft. Remove the
tool.

f Install and tighten the washer, spring

washer and screw.
G0865431

1810745-02 79
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

Assembly of friction blocks

3 Fitting the friction blocks.

Guide pin

a Fit the friction blocks onto the

guide pins

NOTE

Be sure that the pins on the

back of the blocks project into
the grooves in the clutch hub.

NOTE

50 Hz = 5 Friction blocks
60 Hz = 3 Friction blocks

b Place the cover in position and secure it with

the snap ring.

Snap ring

Cover
G0865451

80 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

4 Fitting the motor.

a Fit a lifting sling to the motor.

Use a shackle from the
separator lifting tool.
Weight of motor with
coupling: approx. 170 kg.

ING
WARN
!
b Lower the motor (while
supported) on to the
separator frame. Crush hazard
It will set on the ledge. If not supported, the motor with
coupling may drop when lifted.

c Fit the screws.

Do not tighten until the
belt has been mounted.

d Connect the electrical cables.

G0864641
5 Fitting the flat belt.

a Fit the flat belt to the motor belt

pulley.

b Tighten the two upper screws.

c Tighten all motor attachment

screws.

ING
WARN
!

Crush hazard
The motor will come off if the
screws are unscrewed.
G0858851

1810745-02 81
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

2.9.2 Driving device

1 Fitting the bottom bearing holder.

a Fit the wing insert, O-rings

and strainer. NOTE

Clean the strainer before fitting.

b Secure the wing insert

with the screw secured d Thread the bottom bearing
with Loctite 243 holder into the frame and fit
c To secure the bottom
the tool into the bottom
bearing holder into the
bearing housing.
frame, apply Loctite
222 on the surfaces
directly above and
below the upper O-
ring.

Socket

Tool

Bottom bearing holder

e Tighten the holder to a torque of 200 Nm.

G0866191

82 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2 Fitting the labyrinth ring.

Frame
a Lubricate and fit the
labyrinth ring o .

G0866371

1810745-02 83
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

3 Fitting the ball bearing and top bearing seat o to the spindle.

a Heat the top bearing seat in oil to b Fit the ball bearing.
maximum 125 °C.
ING
WARN NOTE
!
Always fit a new bearing.
Burn hazard Pre-lubricate before fitting.
Use protective
gloves when
handling any heated
parts.

c Fit the snap ring.

ING
WARN
!

Risk for eye injury from flying snap ring

Use the correct pliers for assembly of snap ring to
avoid accidental release.

d Heat the top bearing seat Puller

together with the bearing in oil to
maximum 125 °C.
Sleeve

e Wipe off the spindle

and fit the top bearing
seat to the spindle
using the sleeve and
puller.

NOTE

Make sure to fit the bearing seat

correctly or it might get stuck!
G0984831

84 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

4 Fitting the top bearing housing.

a Fit the axial springs o to the top

bearing housing.

Axial springs
b Carefully lower the bowl spindle.
Make sure that the springs enter the
recesses on the top bearing seat.

c Lubricate the threads before

assembly.

d Fit the composite springs o and

plugs to the top bearing housing.
Do not tighten the plugs.
Make sure that the springs enter the
recesses in the top bearing seat.
The plugs should be tightened when
the spindle assembly is mounted into
the frame.
G0866621

1810745-02 85
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

5 Fitting the spindle pulley.

a Turn the spindle assembly

upside down.

b Wipe off the spindle pulley c Fit the spindle pulley

seat on the spindle and nave firmly on the bowl
bore in the spindle pulley with spindle.
a dry cloth.

NOTE

At least 1mm free space between

support and spindle assembly to
protect the bearing.

Mount the cap nut to protect the

threads and support the spindle.

G0866731
6 Fitting the self-aligning roller bearing o .

a Heat the bearing in oil to maximum

125 °C.
b Lower the bearing
NOTE onto the spindle
and press down
Always fit a new bearing. onto the spindle
Pre-lubricate before fitting. pulley using the
special drift tool.

ING
WARN
!

Burn hazard
Use protective gloves when
handling the heated bearing.
G0866841

86 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

7 Fitting the oil pump.

a Fit O-ring onto lubrication oil orifice. Spread oil film on c Lubricate all threads before
O-ring. assembly.
b Push lubrication oil orifice into oil pump. Be sure to
line up tabs on orifice with slots in pump.

d Fit the oil pump (65 + 5 Nm) using

spanners.

NOTE

Clean the oil pump and make

sure that the bottom hole is not
clogged.

G0866961

1810745-02 87
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

8 Fitting the fan

a Turn the spindle assembly up-side down.

NOTE

Ensure that the spindle is seated against

the inner ring of the ball bearing.

b Apply a thin layer of silicone grease

Silicone grease and fit the O-ring o into the fan.

NOTE

Make sure that the bearing

is pre lubricated before
fitting the fan.

c Place a spanner (or similar) on the spindle pulley

key-grip, as holder-up and fit the fan. Tighten
firmly, by hand, with the pin spanner.

Key-grip

G0924031
9 Fitting the air deflector.

a Turn the spindle assembly up-side

down and fit the air deflector.
G0859231

88 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

10 Lowering the spindle assembly into the frame.

a Remove the cap nut from the spindle.

Fit the lifting tool to the spindle assembly and lift it.

ING
WARN
!

Crush hazard
Do not rotate the spindle assembly during lifting. The spindle
assembly may otherwise come loose from the lifting tool.

NOTE

Check that the hole at the bottom of the oil pump is clean before
lowering the assembly down.

Carefully blow
compressed air
b Position the flat belt o so
through the hole in
the bearing housing. that the spindle assembly can
pass through when lowering.
Check the bottom hole. See note below.

c Carefully lower the spindle assembly and position

the bolt holes over the threaded frame holes.
Make sure that the bottom bearing, enters the
bottom bearing holder correctly. Do not use force.

ING
WARN
! Space

Cut hazard
Do not put fingers between the frame and air
deflector while lowering the assembly.

d Fit and tighten the screws.

NOTE

Check the direction arrows on the belt and the

machine plate for correct position.

Make sure that the belt does not get smudged

with oil or grease during handling.
e Tighten the plugs firmly.
G0867971

1810745-02 89
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

11 Fitting the flat belt.

a Lift up the belt to the middle (centre) of the

spindle pulley.

NOTE

For correct position,

centre the belt on the
spindle pulley camber.

Clearance

b Fit the flat belt to the motor belt pulley.

c Tighten the two upper screws.

d Tighten all motor attachment screws.

NOTE

Do not turn the spindle until the

motor is tightened properly to the
frame.

G08588B1

90 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

12 Fitting the neck bearing cover and deflector ring.

a Apply a thin layer of silicone grease and fit the O- Deflector ring
rings and the seal ring in the lower groove o

b Fit the neck bearing cover.

NOTE Neck bearing cover

The guide pin on the cover should enter one of

the two holes in the bearing housing.

c Push the deflector ring

down until it stops.

G0868051

1810745-02 91
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

13 Fitting the operating water cover.

O-ring

a Lubricate with oil and fit the seal

ring and O-ring o into the
operating water cover.

Renew the O-ring o

b Fit the operating water cover. Fit washers
and tighten the screws.

NOTE

The water pipe in the frame should

enter the hole in the cover.

G0868141
14 Measuring the radial wobble of the bowl spindle.

a Fit a dial indicator in a support

and fasten it in position as
illustrated. Use the flat belt to NOTE
turn the spindle.
Permissible radial wobble: max. 0,04
mm. If the spindle wobble exceeds
this value, contact an Alfa Laval
representative.

Max. 0,04 mm
G0858711

92 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

15 Fitting the clutch cover.

b Tighten the screws.

G0858141
a Fit the clutch cover.

16 Fill oil in the oil sump.

NOTE

The separator should be level and at

standstill when oil is filled.

a Remove the oil pin, plug and washer.

b Fit new washer i and refit the drain

plug.
c Fill with new oil until oil flows out from
the filler hole.
The oil volume should be 2,1 litres
d Fit new O-ring i onto the oil pin. when filled.
e Refit the plug with new washer i
NOTE
f Fit the oil pin.
For grade and quality of oil see
G0868781

2.11.6 Lubricating oils, page 120

1810745-02 93
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

2.9.3 Bowl

1 Check for impact marks and corrosion in bowl

body nave and on spindle taper i o .

a Remove any impact marks using

N
CAUTIO a scraper and/or a whetstone.
!

Disintegration hazard
Impact marks may cause the separator to
vibrate while running.

b Rust can be removed by using a

fine-grain emery cloth (e.g. No. 320).

c Finish with polishing paper (e.g. No. 600).

d Lubricate to prevent further corrosion.

G0874611
2 Fitting new valve plugs on the operating slide i i .

a Remove the valve plugs using b Carefully tap in new valve plugs, using a
a drift. clean, soft-faced hammer.

Drift NOTE

Make sure that the plugs are fitted as

described in the illustration.
G0874841

94 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

3 Fitting the operating slide.

a Apply a thin layer of silicone grease and fit the

rectangular ring on the operating slide and the b Fit the operating slide.
rectangular ring and O-ring on the bowl body.
i o . NOTE

The guide pin in the bowl body

should enter the hole in the
operating slide (this hole is
marked with a drill mark).

Nozzle secured with Loctite 243

Alignment hole

Operating slide

Bowl body

Guide pin

G0861241
4 Fitting the operating slide holder.

a Fit the holder over the

operating slide.
b Apply a thin layer of molykote grease
and fit and tighten the screws.

G0861331

1810745-02 95
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

5 Fitting the operating water ring.

NOTE
a Fit the ring i
The discoloration on the ring is oxide protection.
Do not clean with abrasives.

b Apply a thin layer of silicone grease

and fit the O-ring i o

c Fit the operating water ring.

NOTE

The drilled assembly mark on the water ring should

face the corresponding mark on the bowl body.

c Grease, fit and tighten the screws.

G0861441

96 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

6 Lifting the bowl body onto the spindle taper.

a Put a drop of oil on the spindle taper.

b Wipe off the spindle taper and

nave bore with a dry cloth.

c Turn the bowl body over.

ING
WARN
!

Crush hazard
Support the bowl body when turning to
prevent it from rolling.

d Fit the lifting

tool and lift the
bowl body.

e Carefully lower the bowl body

onto the spindle taper.

f Remove the lifting tool.

G0861731

1810745-02 97
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

7 Fitting and tightening the cap nut.

a To prevent the bowl body from rotating

when fitting the cap nut;
Fit the compressing tool to the bowl b Apply a thin layer of
body and fit a screw together with a molykote grease. Fit and
socket into the frame, as shown in the tighten the cap nut to a
illustration. torque of 50 Nm.

NOTE

Left-hand thread!

Compressing tool

Screw

Socket (or similar)

G0861851
Cap nut

98 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

8 Fitting the discharge slide.

a Apply a thin layer of silicone grease and

fit the rectangular ring i o .

O-ring

b Apply a thin layer of silicone grease

and fit the O-ring i o

ING
WARN
!
c Fit the lifting tool and
lower the discharge
slide into the bowl. Crush hazard
The ring on the lifting tool must be
pushed home against the discharge
d Remove the lifting tool. slide, otherwise it may come loose
from the tool.

e Fit the nut.

f Fit the spanner for nut and

tighten the nut with a torque
wrench to a torque of min.
100 Nm.

g Remove the compressing tool and the

G0861951

spanner for nut.

1810745-02 99
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

9 Assembly of the disc stack.

a Fit the discs one by one onto the distributor.

The distributor has a guide rib for the correct
ING
positioning of the bowl discs. Always end with WARN
!
the disc without caulks.

The number of discs may have to be increased

to adjust the disc stack pressure. Always check
before operating the separator. See ‘‘Checking
the disc stack pressure .” on page 106

N
CAUTIO
!

Cut hazard
Sharp edges on the bowl discs may cause
cuts.

Recess on bowl disc

Guide rib on distributor

G0862051

100 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

10 Fitting the disc stack assembly to the bowl body.

a Fit the lifting tool into the

distributor.

b Lower the disc stack into the bowl.

Guide pin on bowl

NOTE body

The guide pin on the bowl body should face

the guide rib on the distributor.

The guide ribs inside the distributor then

enter the recesses on the bowl body nave.

Guide rib on
distributor

Guide ribs inside the distributor.

Recesses on the bowl body nave.

G0862171

1810745-02 101
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

11 Assembling the paring tube i .

Tolerance ring

a Fit the O-rings i bearings

i and tolerance ring to the
paring tube.

G0984961
12 Mounting the paring tube and fitting the inlet and outlet pipe.

a Insert the
paring tube b Mount the splash sealing
and mount
the axial
support to
the inlet and
outlet pipe.
c Apply a thin layer of
silicone grease and fit d Carefully lower the
the O-rings i o inlet and outlet pipe
assembly into the
top of the
distributor.
G08622B1

102 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

13 Fitting the top disc.

a Move the paring tube

b Lower the top disc. to the centre.

The guide rib on the

distributor should enter
one of the two larger
recesses on the top disc.
NOTE

To avoid damaging
the paring tube, turn
it towards the centre
of the pipe.

G0862341

1810745-02 103
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

14 Fitting the bowl hood.

a Apply a thin layer of silicone grease and fit the

O-ring i o

b Fit the seal ring i o Press

the ring down evenly until two
bulges appear.

c Carefully tap down the bulges alternately with a

soft rubber mallet, until the ring is completely fitted.

d Fit the lifting tool and lower the bowl

hood so that its recess fits into the guide
pin in the bowl body.

Recess on bowl hood

Guide pin on bowl body

e Remove the lifting tool.

G0862421

104 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

15 Fitting the lock ring.

a Place the lock ring on the bowl hood

with its guide pin close to the
corresponding hole in the bowl
body.

NOTE

Make sure that the groove in

the bowl body which retains
the lock ring is clean.

b Fit the compressing tool and

compress the disc stack by
alternately turning the screws a
NOTE
maximum of 40 Nm at a time until
the lock ring fits into the bowl
body. The lock ring is correctly Check that the lock ring is
fitted when the lock ring ends are correctly positioned all way
facing each other. around!

c Release the pressure on the

compressing tool and remove it.

Lock ring

Bowl hood
NOTE

Bowl body Never remove any material

from the lock ring. A
hazardous situation could
result.
G0862531

Before compressing Lock ring in position

1810745-02 105
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

16 Checking the disc stack pressure i i .

a Remove bowl hood, top disc and inlet and outlet pipe.

b Add one disc to the disc stack.

c Refit the disc without caulks, the top disc

and bowl hood.

d Fit the lock ring and fully

compress the disc stack with the
compressing tool.
NOTE
NOTE

Always refit the disc

Do not use more power than
without caulks on top
40 Nm/screw at a time,
of the disc stack!
alternately.

e If the lock ring enters the groove,

repeat a-d until the lock ring does
not enter the groove.

f Dismantle the bowl and remove

one disc to get the correct disc
stack pressure.

g Assemble the bowl with inlet and

outlet pipe.
G0874961

106 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.9.4 Frame hood

1 Fitting the frame hood i o .

a Turn the paring tube so that the frame hood can

pass the paring tube. NOTE

Paring tube. Make sure that the frame

b Apply a thin layer of silicone grease and hood is mounted in its
fit the O-ring onto the frame hood correct position
i o according to the piping
arrangement.
c Lower the frame hood.

d Fit and tighten the

screws.

NOTE

G0863771
Make sure to fit the frame hood
groove and the projection of the
pipe.

1810745-02 107
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

2 Control measurement of paring disc height o .

a Remove the guide screw (A).

D Quantity height
b Measure the distance D. adjusting rings
mm
Assemble the correct
number of height 32 ± 0,5 3
adjusting rings (B)
according to the table. 31 ± 0,5 2

30 ± 0,5 1

c Refit the guide screw (A)

Height adjusting rings Guide screw

Support ring

Frame hood

Important!
Bowl hood

Paring disc

Distributor
G09115B1

108 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

3 Fitting the spring and arm.

Spring
a Fit the spring on the arm
and fit the arm to the top
of the paring tube end.

Arm
Pin Paring tube

b Fit the spring to the pin

on the frame hood and
make sure that it is
properly attached on
both ends.

G0863781

1810745-02 109
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

4 Fitting the connection housing.

a Fit the connection housing over

the inlet/outlet pipe.

NOTE

Make sure that the screw, on top of

the frame hood, enters the guide
hole at the underside of the
connecting housing.
b Fit the washer and the lock
nut using the hook spanner.

G0863941

110 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.9.5 Unbalance sensor (option)

1 Fitting the unbalance sensor holder.

a Remove the cover.

Sensor holder.

Sensor arm Frame

Screw M8 b Fit the O-ring on the holder.

Fit the screw into the holder and
M10 mount the holder into the
separator frame.

Sensor
holder

O-ring NOTE

If removing the sensor holder;

use a M10 screw as a puller.

NOTE

See next page for fitting and

correct adjustment of the sensor.
G0873481

1810745-02 111
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

2 Adjusting the unbalance sensor

a Measure the distance (A) from the sensor

arm (inside the frame) to the edge of the
holder, using a sliding calliper.

b Measure the length (B) of the sensor.

A
Holder edge

Sensor arm

c Fit the sensor into the holder. Do not forget the nut.

C d Adjust the sensor so that the distance (C) is B - A + 1,5 mm.

1,5 mm
Nut
Sensor

Nut.
+ = brown or red

J = black or white 24 V DC

0V = blue

e When correct distance is achieved tighten the nut Adjustment value (approx. distance 1,5 mm) for the sensor
is; 12 mA ± 1mA.
against the holder. For more details see ‘‘Connection List” on page 15
Fit the cover (see previous page). and‘‘752 Unbalance sensor (option).” on page 22
G0873461

112 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.10 Actions After Assembly

2.10.1 Control of machine plates and

safety labels o
Alfa Laval ref. 561498 rev. 2

1 Check that the following signs are attached.

Machine plate

Lifting instructions

Space for label indicating representative.

Safety label.

Space for additional label as specified.

S0 0 5 0 1 7 1
S0050181

Indicating direction of rotation of horizontal

driving device.

1810745-02 113
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

2 Check legibility. Following texts should be read on the labels.

Separator S 825
Manufacturing serial No. / Year
Product No. 881201-02-01
In and outlet device 564176-01
Bowl 564214-01
Machine bottom part 564504-01
Bowl speed synchronous 7118 r/minute (50 Hz)
7081 r/minute (60 Hz)
Direction of rotation (bowl) ¬
Speed motor shaft 3000 r/min (50 Hz),3600 r/min (60 Hz)
El. current frequency 50/60 Hz
Recommended motor power 4,9 kW
Max. density of feed 1100 kg/m3
Max. density of sediment 2327 kg/m3
Max. density of operating liquid 1000 kg/m3
Process temperature min./max. 0/100 °C

DANGER
Read the instruction manuals before installation, operation and maintenance.
Consider inspection intervals.
Failure to strictly follow instructions can lead to fatal injury.
If excessive vibration occurs, stop separator and keep bowl filled with liquid
during rundown.
Out of balance vibration will become worse if bowl is not full.
Separator must stop rotating before any dismantling work is started.

Read instruction manual before lifting.

114 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.11 Oil Change

The separator should be level and at
standstill when oil is filled or the oil level is
checked.

2.11.1 Lubricating oil

Do not mix different oil brands.
Always use clean vessels when handling lubricating oil.
Great attention must be paid not to contaminate the lubricating oil. Of
particular importance is to avoid mixing of different types of oil. Even a
few drops of motor oil mixed into a synthetic oil may result in severe
foaming.
Any presence of black deposits in a mineral type oil is an indication that
the oil base has deteriorated seriously or that some of the oil additives
have precipitated. Always investigate why black deposits occurs.
If changing from one oil brand to another it is recommended to do this
in connection with an overhaul of the separator. Clean the gear housing
and the spindle parts thoroughly and remove all deposits before filling
the new oil.

NOTE

Always clean and dry parts (also tools) before lubricants are applied.

ON
CAUTI
!

Check the oil level before start. Top up when necessary.

Oil volume = see “Technical Data”.
It is of utmost importance to use the lubricants recommended in our
documentation.
This does not exclude, however, the use of other brands, provided they
have equivalently high quality properties as the brands recommended.
The use of oilbrands and other lubricants than recommended, is done
on the exclusive responsibility of the user or oil supplier.

Applying, handling and storing of lubricants

Always be sure to follow lubricants manufacturer's instructions.

1810745-02 115
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

2.11.2 Check oil level

1 Remove the oil pin and make sure that the oil
level is above the lower end of the pin.

2.11.3 Oil change procedure

1 Remove the oil pin, plug and washer.
2 Remove the drain plug.

ON
CAUTI
!

Burn hazard
The lubricating oil and various machine surfaces can Oil fill
be sufficiently hot to cause burns.
Oil drain

3 Collect the oil in a vessel.

4 Fit and tighten the drain plug.

5 Fill with new oil until oil flows out of oil filler
hole.

G0868771
NOTE

See 2.11.6 Lubricating oils, page 120.

NOTE

For Intermediate service procedures; See

6 Fit the washer and the oil filling plug. Tighten “Fill oil in the oil sump.” on page 93.
the plug.
7 Fit the oil pin.

116 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.11.4 Lubrication chart

Alfa Laval ref. 567329-01, rev. 0

Bowl (3), Rubber seal rings (4)

Electric motor (6)

Bowl spindle taper (2)

Buffers (3)

Bowl spindle and bearings (1)

Friction clutch bearings (5)

G0875441
Lubricating points Type of lubricant Interval
1 The oil bath. Bowl spindle bearings See 2.11.1 Lubricating oil, page 115 Oil change:
are lubricated by oil mist from the oil Volume: 2.1 Technical Data, page 13 1. Continous operation: 4000 hours
bath. Ambient temperature 0 to +55°C 2. Seasonal operation:
before every operating period
3. Short periods operation:
12 months even if total numbers of
operating hours is less than stated
above

2 Bowl spindle taper. Lubricating oil, only a few drops for At assembling
rust protection.

3 Bowl: Sliding contact surfaces, thread Pastes specified in 2.11.5 Lubricants, At assembling.
of lock nut and cap nut. page 118

4 Rubber seal rings. Grease as specified in 2.11.5 At assembling

Lubricants, page 118

5 Friction clutch bearings. The bearings are pre-lubricated with No need for extra lubrication.
grease.

6 Electric motor. Follow the manufacturer’s instructions. Follow the manufacturer’s instructions.

NOTE ON
CAUTI
!
Check and pre lubricate new spindle bearings and
those that have been out of service for six months or
longer. Check the oil level before start.
If not otherwise specified, follow the suppliers Top up when necessary.
instructions about applying, handling and storing of Do not overfill.
lubricants.

1810745-02 117
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

2.11.5 Lubricants
Alfa Laval ref. 553217-01 rev. 8

Pastes for non-food applications:

NOTE

The data in below tables is based on supplier

information in regards to lubrication properties.
Trade names and designations might vary from
country to country, contact your local supplier for
more information.

Brands with Alfa Laval article numbers are approved

and recommended for use.

Manufacturer Designation Alfa Laval No.

Fuchs Lubritech Gleitmo 805 K

Gleitmo 705 K

Dow Corning Molykote 1000 (Paste) 537086-02 (1000 g)

Molykote 1000 (Paste) 535586-01 (100 g)
Molykote G-rapid plus 535586-02 (50 g)
(Paste)

Rocol Antiscuffing (ASP) (Paste)

Kluber Wolfracoat C (Paste)

Bonded coatings

Manufacturer Designation Alfa Laval No.

Fuchs Lubritech Gleitmo 900 (Varnish or

spray)

Dow Corning Molykote D321R (Spray) 535586-01 (300 ml)

Molykote D321R (Varnish) 535586-02 (60 ml)

118 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

Silicone grease for rubber rings

Manufacturer Designation Alfa Laval No.

Dow Corning Molykote 111 (Compound) 539474-02 (100 g)

Molykote 111 (Compound) 539474-03 (25 g)

Fuchs Lubritech Gleitmo 750

Kluber Unisilkon L 250 L

Wacker Silicone P (Paste)

Greases for ball and roller bearings:

NOTE

Always follow the specific recommendation for

lubrication as advised by the manufacturer.

Manufacturer Designation

BP Energrease MM-EP2
Energrease LS2

Castrol APS 2 Grease

EPL 2

Chevron Dura-lith grease EP2

Elf Epexa 2

Esso/Exxon Beacon EP2

Unirex N2

Fina Marson EPL 2A

Mobil Mobilith SHC 460

Mobilux EP2

Gulf Gulflex MP2

Q8/Kuwait Petroleum Rembrandt EP2

Shell Alvania EP Grease 2

Albida Grease EP2

SKF LGEP2 or LGMT2

Texaco Multifak AFB 2

1810745-02 119
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

2.11.6 Lubricating oils

Alfa Laval ref. 567330-01, rev. 1

Paraffinic mineral lubricating oil, category

(ISO-L-) HM 68.
Viscosity grade (ISO-3448/3104) VG 68.
The oil shall follow the requirements in one of
the standards below.

Standard Designation

DIN 51524 part 2 (German standard) DIN 51524-HLP or HVLP 68

ISO 11158 (International standard) ISO-L-HM or HV 68

The following is the list of recommended oil

brands. Trade names and designations might
vary from country to country. Please contact your
local oil supplier for more information.

Manufacturer Designation

Alfa Laval 567334-01 1 litre

567334-02 4 litres

BP Bartran 68
Bartran HV 68

Castrol Hyspin AWS 68

Hyspin AWH 68

Chevron Hydraulic oil AW 68

Esso / Exxon Nuto H 68

Univis N 68

Mobil DTE 26 (ISO VG 68)

DTE 16 (ISO VG 68)
DTE 16M (ISO VG 68)

Shell Tellus Oil 68

Tellus Oil S 68
Tellus Oil T 68

Statoil HydraWay HMA 68

Hydra Way HVX 68

Total Fina Elf Azolla ZS 68

Lubmarine Visga 68

The list of recommended oil brands is not complete. Other oil brands may
be used as long as the follow the above standards and have equivalent
high quality as the brands recommended. The use of other lubricants
than recommended is done on the exclusive responsibility of the user or
oil supplier.

120 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2.12 Lifting instructions

2.12.1 Lifting the separator

Weight to lift 200 kg

Sling length: Min. 750 mm

Fasten all four bolts. Tightening

torque 35 - 40 Nm

G0868451
1 Remove the inlet and outlet device, the frame
hood and the bowl according to the
instructions in 2.7 Dismantling, page 39.

NOTE

Never lift or transport the separator with the bowl

still inside.

2 Disconnect all connections.

3 Fit the lifting tool (not included in set of tools).
All four bolts on the lifting tool must be
fastened to the frame.

4 Use two lifting slings to lift the separator. Total

length of each loop: minimum 1,5 metres.
5 Unscrew the foundation bolts.

1810745-02 121
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 825 SEPARATION SYSTEM SERVICE MANUAL

6 When lifting and moving the separator, follow

normal safety precautions for lifting large
heavy objects.

ING
WARN
!

Crush hazards
A falling separator can cause accidents resulting
in serious injury and damage.
Never lift the separator by any other method than
described in this manual.

NOTE

When lifting parts without weight specifications,

always use lifting straps with the capacity of at
least 500 kg.

2.12.2 Lifting the bowl

When lifting and moving an assembled bowl, Weight to lift 40 kg

always follow these instructions.

1 Fit the lifting tool with lifting eyes to the bowl

assembly.
2 Check that the lock ring is mounted correctly Tightening torque 35 - 40 Nm
before lifting the complete bowl.
3 Lift the bowl using a sling with the proper
rating.
Lock ring

NOTE
Make sure that
Never try to lift the bowl while it is still in the frame. lock ring is fitted.
G0868441

The bowl body is fastened to the frame with the

cap nut.

122 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

1810745-02 123
3 CHANGE OF CIRCUIT BOARD SA 825 SEPARATION SYSTEM SERVICE MANUAL

3 Change of Circuit Board

If a circuit board has to be changed, proceed as
follows:
Note down the run time (days only) as shown in
the function list of the EPC 50.
Change the board according to the instructions
below.
Go to parameter Fa 90, and insert the run time.

OP-Board
· Switch power off.
· Remove the snap-in transparent cover.
· Disconnect the two cable plugs (do not
remove the cables from the plugs).
· Disconnect the flatcable connector at the top.
· Unscrew the five hexagon nuts.
· Mount the new board, and connect in reverse
order.

I/O-Board
· Switch power off.
If there is no optional board installed:
· Disconnect all the cable plugs on the large
board (do not remove the cables from the
plugs).
· Unscrew the hexagon nuts. Take care to note
where the special nuts for optional board(s)
are located.
· Mount the new board, and connect in reverse
order.

124 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 3 CHANGE OF CIRCUIT BOARD

If one or more optional board is installed:

· Switch power off.
· Disconnect the cable plug(s) on the optional
board (do not remove the cables from the
plug(s)).
· Disconnect the flatcable connector at the top.
· Unscrew the three hexagon nuts.
· Note the position of the board and remove the
board.
· Disconnect all the cable plugs on the large
board (do not remove the cables from the
plugs).
· Unscrew the hexagon nuts. Take care to note
where the special nuts for optional board(s)
are located.
· Mount the new board in the same position as
the old, and connect in reverse order.

MT-Board
· Switch power off.
· Disconnect the cable plug (do not remove the
cables from the plug).
· Disconnect the centrally connected cable.
· Unscrew the four screws holding the board
and lift out the board.
· Mount the new board, and connect in reverse
order.
· Check that the central hexagon nut is properly
tightened.

1810745-02 125
3 CHANGE OF CIRCUIT BOARD SA 825 SEPARATION SYSTEM SERVICE MANUAL

3.1 Circuit Board

Temperatures
Circuit board temperature information can be
read as follows:
· Set Pr 7 = 2.
· Push ‘+’ and ‘–’ at the same time (‘Standst.’
now shows on the display).
· Push ‘–’
The actual temperature, max. temperature, and
the number of times the temperature has been
above 70 °C for the transducer scrolls across the
display.
· For further circuit board temperatures, push
the ‘–’ button.
· To leave the list push the ‘+’ and the ‘–’ buttons
at the same time.
· Reset Pr 7 = 0.

126 1810745-02
SA 825 SEPARATION SYSTEM SERVICE MANUAL 4 CLEANING IN PLACE

4 Cleaning in Place
The use of Cleaning In Place (CIP)
equipment is recommended for best
separation results. For further information
concerning the CIP equipment, see the CIP
booklet, bookno. 1817261.

Before connecting the CIP equipment to the

Separation System, the switch on the control
cabinet must be turned to the CIP position.
This is so that oil is not accidentally pumped
when the pipeline is opened up.

4.1 Cleaning in Place,

Separator
1 Remove the pipe connecting plate with pipes
from the separator.
2 Attach the CIP equipment as shown in the
illustration.

NOTE

The top outlet on the CIP unit should be connected to

the top inlet on the separator.

G065054A
The middle inlet on the CIP unit should be connected
to the middle oil outlet on the separator.
The lower CIP inlet should be connected to the lower
water outlet on the separator.

1810745-02 127
4 CLEANING IN PLACE SA 825 SEPARATION SYSTEM SERVICE MANUAL

128 1810745-02