Status: Approved Confidential Document id: DBAD695805 - Page 1 (87)

Instruction Book
Separator for purification of crankcase ventilation gas
PureVent 2.0

Specification No. 881273-04-01/2

Book No. 9011706-02, rev. 2
Status: Approved Confidential Document id: DBAD695805 - Page 2 (87)

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden

Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40

© Alfa Laval Tumba AB 05-2015

The original instructions are in English
The content of this manual may be subject to
changes without prior notice.
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of Alfa
Laval Tumba AB.
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Contents
1 Read this first 7

2 Safety instructions 9
2.1 Warning signs in text 13
2.2 Environmental issues 14
2.3 Requirements of personnel 15
2.4 Remote start 15

3 General information 17

4 Technical description 19
4.1 Working principle 19

5 Operating instructions 21
5.1 Operating routine 21
5.2 Before first start 21
5.3 Start 22
5.4 Operation 23
5.5 Stop 23

6 Maintenance and fault finding 25

6.1 Separator unit 25
6.1.1 Daily inspection 25
6.1.2 Every 16 000 hours of operation 26
6.1.3 Every 16 000 hours of operation or at least every
5 years 28

6.2 Frequency drive 29

6.2.1 Instructions for VACON 100X 30
6.2.2 Replacing Frequency drive 41

7 Technical references 43
7.1 Product description 43
7.1.1 Declaration 44

7.2 Technical data 46

3
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7.3 Basic size drawing 47

7.4 Connection list 49
7.5 Function Requirement Specification
(FRS) 50
7.5.1 General 50
7.5.2 References 50
7.5.3 Definitions 51
7.5.4 Description of operation modes 51
7.5.5 Alarms 53
7.5.6 Parameters 54
7.5.7 Additional functions 55
7.5.8 Handling of connection interfaces 56
7.5.9 Installation 58

7.6 Set of tools 74

7.7 Motor data 75
7.7.1 Y-connect motor (400 V) 75

7.8 Lifting instructions 76

7.9 Connection diagram 77
7.10 Machine plates and safety labels 79

8 Installation 81
8.1 General information 81
8.1.1 Connections 81
8.1.2 Foundation drawing 83

8.2 Installation 84
8.3 Storage and transport of goods 85
8.3.1 Storage 85
8.3.2 Transport 85
8.3.3 Transport of goods 85

9 Spare parts 87

4
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Study instruction manuals and observe the

warnings before installation, operation,
service and maintenance.

Not following the instructions can result

in serious accidents.

In order to make the information clear only

foreseeable conditions have been considered.
No warnings are given, therefore, for situations
arising from the unintended usage of the
machine and its tools.

5
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!
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1 Read this first

This Instruction Book is designed for operators

and service engineers working with the Alfa
Laval separator PureVent.

If the separator has been delivered and installed

by Alfa Laval as a part of a processing system,
this manual should be viewed as part of the
System Documentation. Study carefully all
instructions in any System Documentation.

This Instruction Book consists of:

Safety Instructions
Pay special attention to the safety instructions
for the separator. Not following the safety
instructions can cause accidents resulting in
damage to equipment and serious injury to
personnel.

General information
Read this chapter if you are not familiar with this
type of separator.

Technical description
Description of the function of the parts of the
separator.

Personnel who deal with advanced maintenance

and service must have a thorough knowledge
of this section.

Operating instructions

This chapter contains instructions for usage of

the separator.

Maintenance and fault finding

This chapter gives instructions for daily checks,
cleaning, servicing and check points.

Technical reference

This chapter contains technical data concerning

the separator.

Installation
General information on installation planning.
Instructions for the installation of the separator.

7
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1 Read this first

Spare parts
PureVent include a centrifuge rotor that rotates
at approx. 7100 rev/minute.

As long as the unit is sealed, fixed mounted

and operated according to instructions and
specifications it is considered to constitute no
danger.

• Use the unit only for the purpose and

parameter range specified by Alfa Laval.
• Strictly follow the instructions for installation,
operation and maintenance.
• Ensure that personnel are competent and
have sufficient knowledge of maintenance
and operation.
• Use only Alfa Laval genuine spare parts
and the special tools supplied.

NG
WARNI
!
Disintegration hazard
If excessive vibrations occur, stop the unit.

NG
WARNI
!
Entrapment hazard
Make sure that rotating parts inside the separator have
come to a complete standstill before moving the
unit or starting any dismantling work.

To avoid accidental start, switch off and make sure the

main switch is in the "OFF" position before starting
any dismantling work.

Warning label
A warning label is placed on the gas separator
unit.

The interpretation of the label is:

STOP! Read the instruction manual before

installation, operation and maintenance. ! WARNING
Consider inspection intervals.
Read the instruction
manuals before
installation, operation
and maintenance.
Consider inspection Separator must stop
intervals. rotating before any
Failure to strictly follow dismantling work is
instructions can lead to started.
fatal injury.
9017573-02-V0

8
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2 Safety instructions
!
The centrifuge includes parts that rotate at high
speed. This means that:
• Kinetic energy is high.
• Great forces are generated.
• Stopping time is long.

Manufacturing tolerances are extremely fine.

Rotating parts are carefully balanced to G0010421

reduce undesired vibrations that can cause

a breakdown. Material properties have been
considered carefully during design to withstand
stress and fatigue.

The separator is designed and supplied for a

specific separation duty (type of liquid, rotational
speed, temperature, density etc.) and must not
be used for any other purpose.

Incorrect operation and maintenance can result

in unbalance due to build-up of sediment,
reduction of material strength, etc., that
subsequently could lead to serious damage
and/or injury.

The following basic safety instructions therefore

apply:
• Use the separator only for the purpose
and parameter range specified by Alfa
Laval. Applies not only to the process
but also to cleaning and service liquids.
• Strictly follow the instructions for
installation, operation and maintenance.
• Ensure that personnel are competent
and have sufficient knowledge of
maintenance and operation, especially
concerning emergency stopping
procedures.
• Use only Alfa Laval genuine spare parts
and the special tools supplied.

9
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!
2 Safety instructions

Disintegration hazards
• If power cables have been disconnected,
always check direction of motor rotation.
Incorrect direction rotation can cause vital
rotating parts to unscrew.
• This can be done by checking the rotation
on the motor fan.

• If excessive vibration occurs, stop

separator.

• Use the separator only for the purpose and kPa

3
m /h

parameter range specified by Alfa Laval. 3

kg/m o
C

r/min
Hz

• Do not change the variable frequency drive

data, it is extremely important that the
frequency does not exceed the allowed
maximum, to avoid serious break down by
too high speed.
• Welding or heating of parts that rotate can
seriously affect material strength.

• Inspect regularly for corrosion and erosion

damage. Inspect frequently if process or
cleaning liquid is corrosive or erosive.

Fall hazard
• Do not stand on the separator or separator
parts.

10
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!
2 Safety instructions

Entrapment hazards
• Make sure that rotating parts have come
to a complete standstill before accessing
parts inside the machine or starting any
dismantling work. Since there is no braking
function the run down time can exceed five
minutes.

• To avoid accidental start, switch off and

lock power supply before starting any
dismantling work.
Assemble the machine completely before
start. All covers, connections and guards
must be in place.

Electrical hazard
• Follow local regulations for electrical
installation and earthing (grounding).

• To avoid accidental start, switch off and

lock power supply before starting any
dismantling work.

• Wait three minutes after separator has

come to complete standstill before starting
any dismantling work.
Conductors may have residual charge.

Crush hazards
• Use correct lifting tools and follow lifting
instructions.

• Do not work under a hanging load.

Noise hazards
• Use ear protection in noisy environments.

11
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!
2 Safety instructions

Burn hazards
• Lubrication oil, machine parts and various
machine surfaces can be hot and cause
burns. Wear protective gloves.

Skin irritation hazards

• When using chemical cleaning agents,
make sure you follow the general rules
and suppliers recommendation regarding
ventilation, personnel protection etc.

• Use of lubricants in various situations.

Cut hazards
• Sharp edges, especially on bowl discs and
threads, can cause cuts. Wear protective
gloves.

12
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!
2 Safety instructions

2.1 Warning signs in text

Pay attention to the safety instructions in this
manual. Below are definitions of the three
grades of warning signs used in the text where
there is a risk for injury to personnel.

NGE R
! DA
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious
injury.

NG
WARNI
!
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.

ON
CAUTI
!
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.

NOTE

NOTE indicates a potentially hazardous situation

which, if not avoided, may result in property damage.

13
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2 Safety instructions

2.2 Environmental issues

Unpacking
Packing material consists of wood, plastics,
cardboard boxes and in some cases metal
straps.

Wood and cardboard boxes can be reused,

recycled or used for energy recovery.

Plastics should be recycled or burnt at a

licensed waste incineration plant.

Metal straps should be sent for material

recycling.

Maintenance
During maintenance oil and wear parts in the
machine are replaced.

Oil must be taken care of in agreement with

local regulations.

Rubber and plastics should be burnt at a

licensed waste incineration plant. If not available
they should be disposed to a suitable licensed
land fill site.

Bearings and other metal parts should be sent

to a licensed handler for material recycling.

Seal rings and friction linings should be

disposed to a licensed land fill site. Check your
local regulations.

Worn out or defected electronic parts should be

sent to a licensed handler for material recycling.

14
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!
2 Safety instructions

2.3 Requirements of personnel

Only skilled or instructed persons are allowed
to operate the machine, e.g. operating and
maintenance staff.

• Skilled person: A person with technical

knowledge or sufficient experience to
enable him or her to perceive risks and to
avoid hazards which electricity/mechanics
can create.
• Instructed person: A person adequately
advised or supervised by a skilled person
to enable him or her to perceive risks and to
avoid hazards which electricity/mechanics
can create.

In some cases special skilled personnel may

need to be hired, like electricians and others.
In some of these cases the personnel has to
be certified according to local regulations with
experience of similar types of work.

2.4 Remote start

If the separator is operated from a remote
position where the separator cannot be seen
or heard the power isolation device shall be
equipped with an interlock device to prevent that
a remote start command could result in gas
being fed to the separator when it is shut down
for service.

The first start after the separator has been taken

apart or been standing still for a long time shall
always be manually supervised locally.

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2 Safety instructions
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3 General information

PureVent is a separator designed to remove oil

droplets and soot from crankcase ventilation gas
in combustion engines. By means of centrifugal
separation, oil and soot is removed from the
vent gas and leaves the separator through a
drain pipe for recirculation or collection. The
PureVent separation efficiency is constant
through maintenance interval and no pressure
drop occurs.

Crankcase gases originate from exhaust

gases that leak down to the crankcase from
the combustion chamber via gaps between
the cylinder wall and the piston rings. This is
also called blow by gases. In order to prevent
pressurizing the crankcase, there must be a
continuous flow of ventilated gases from the
crankcase.

It is desirable from environmental reasons to

feed these gases back into the inlet manifold
for re-combustion ("closed crankcase system").
If this is done without filtering the gas it will
however cause harm to the motor:

• The efficiency of the turbocharger drops as

a consequence of coke deposits.
• The intercooler performance will be
reduced.

The PureVent Separator eliminates these

problems. Gas filtered through the PureVent
separator is clean enough either to be
recombusted or to be ventilated out into the
ambient air without further filtering.

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3 General information
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4 Technical description

4.1 Working principle

The crankcase ventilation-gas enters the inlet
“A” and is purified in the rotating disc stack. The
cleaned gas then leaves the unit through the
outlet “C”.

The separated oil and soot flow down towards

the oil outlet “B” at the bottom.

The frequency converter unit “D” controls the

separator motor through the cables connected
at “F”. The electrical supply to the frequency
converter is connected at “E”.

A
G1104821

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4 Technical description
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5 Operating instructions

5.1 Operating routine

These operating instructions describe routine
procedures to follow before and during the
start, running and stopping sequences of the
separator.

The instructions are related only to the separator

itself.

5.2 Before first start

Before first start ensure the machine is
installed correctly according to the installation
instructions. See 8 Installation on page 81.

Check that all hose connections are fitted

correctly.

Technical requirements for connections and

logical limitations for the separator are described
in the following documents:

1. Technical data
2. Basic size drawing
3. Connection list
4. Functional Requirement Specification
(FRS)

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5 Operating instructions

5.3 Start
Start separator concurrent with the engine it is
connected to.

1. Start the separator by pressing the start

button on the frequency converter (VFD).

NOTE

PureVent may be connected for automatic

operation. If so, no manual starting is needed.

2. Check the separator for vibration. Some

vibration may occur for short periods during
the starting cycle when the separator
passes through its critical speeds. This is A
normal and passes without danger. Try to
learn the vibration characteristics of the
critical speed pattern.

G1071951

A: Measuring points, vibrations

3. The separator has reached full speed

approximately 15 seconds after start.

ON
CAUTI
!
If excessive vibration occurs, stop separator.

At any sign of abnormal vibrations or noise,

shut off unit and contact your Alfa Laval
representative.

4. At first start after installation or if the rotor

has been dismantled or the installation
has been changed, always check the
separator inside pressure for connection
821 according to data in the 7.4 Connection
list on page 49.

22
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5 Operating instructions

5.4 Operation
1. Check that the oil outlet is gas tight and
free from blockage, and connected with
downward slope all the way back to the
engine crank case. The separated oil is
drained from outlet by gravity.

NOTE

Important to fulfill EX-demand.

2. The following checkpoints should be carried

out daily:

- Check all hose connections for

leakage.
- Check the separator for noise and
vibration.
- Check that the oil outlet is free from
blockage.

5.5 Stop
1. Stop the unit by pressing the stop button
on the VFD.

NOTE

PureVent may be connected for automatic

operation. If so, no manual stopping is needed.

2. It takes approximately 2 minute for the

separator to come to complete standstill.
This can be verified by checking the motor
fan.

NOTE

The stopping time can exceed 2 minutes.

G0991081

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5 Operating instructions
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6 Maintenance and fault finding

6.1 Separator unit

PureVent is a product designed for minimal
maintenance. Please follow the maintenance
steps mentioned below to ensure trouble free
operation.

ON
CAUTI
!
Disintegration hazard
At any sign of abnormal vibrations or noise, shut off
unit and contact your Alfa Laval representative.

6.1.1 Daily inspection

• Check all hose connections for leakage.
• Check the separator for noise and vibration.
• Check that the oil outlet is free from
blockage.
• Check that the oil mist inlet piping and
clean air outlet piping are without damages.

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6 Maintenance and fault finding

6.1.2 Every 16 000 hours of

operation
Every 16 000 hours of operation the motor and
disc stack need to be replaced by following the
steps below:

1. Shut down the separator and make sure

0
the main switch is in the "OFF" position.
1

NG
WARNI
! G1109921

Electrical Hazard
Charged capacitors in the frequency converter
may cause electrical shock.
Wait 5 minutes before starting any dismantling
work.

26
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6 Maintenance and fault finding

2. Disconnect the power - and grounding

cables (2) from the motor.

3. Unscrew the 6 screws (1) holding the motor

and disc stack in place.

4. Lift the motor and disc stack out of the

housing using the eye bolts (3) secured 1
with nut (4).
2

ON
CAUTI 3
!
4
cut hazard
Sharp edges on bowl discs can cause cuts.
Wear protective gloves.

5. Clean the inside of the housing (7).

NOTE
5
Wear protective gloves.

6. Inspect the upper and lower oil drains (8)

and verify that they are still open.

7. Replace the O-ring (5) with the one 6

supplied in the spare parts package.

8. Move the eye bolts to the spare motor

housing and lift the new motor and disc
stack in place. 8 7
9. Fit the 6 screws (1), tightening torque 25
Nm.

10. Reconnect power - and grounding cables 9

(2).
10

NG
WARNI G1072031
!
Electrical Hazard
Follow local regulations for electrical installation
and earthing (grounding).

After replacing the motor and disc stack follow

the routines described before first start and start
in 5 Operating instructions on page 21. Pay
particular attention to how to verify direction of
rotation.

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6 Maintenance and fault finding

6.1.3 Every 16 000 hours of

operation or at least every
5 years
At regular intervals (see above) the rubber
isolators (6) need to be replaced.

1. Shut down the separator and make sure

the main switch is in the "OFF" position.

2. Unscrew the separator unit from the

mounting brackets.

3. Disconnect hoses and power cable if

necessary.

4. Lift the unit and unscrew the rubber

isolators.

5. Mount the replacement isolators.

6. Remount the separator.

7. Reconnect power and hoses if necessary.

NG
WARNI
!
Electrical Hazard
Follow local regulations for electrical installation
and earthing (grounding).

28
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6 Maintenance and fault finding

6.2 Frequency drive

The information in this chapter only mentions
basic maintenance of the frequency drive. No
user programming of the unit is recommended,
and Alfa Laval takes no liability for damages
caused by user manipulation of the drive
settings.

Before doing any work on the frequency drive

make sure to shut down the separator and make
sure the main power switch is in the "OFF"
position.

NG
WARNI
!
Electrical Hazard
- Follow local regulations for electrical installation and
earthing (grounding).

- To avoid accidental start, switch off and lock power

supply before starting any dismantling work.

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6 Maintenance and fault finding

6.2.1 Instructions for VACON

100X
Alfa Laval ref. 9016917 Rev. 1

Note: This document is based on the Vacon

‘Installation, Technical and Maintenance
Manual’ and ‘Vacon 100 Application Manual’
The manuals can be found at: “www.vacon.com”
refer to document DPD00534G and
DPD00927F.

NG
WARNI
!
Electrical hazard
Follow local regulations for electrical installation and
earthing (grounding).

To avoid accidental start, switch off and lock power

supply before starting any dismantling work.

To avoid any injuries make sure that the

disconnect switch on the VFD is in OFF-position
and securely locked.

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6 Maintenance and fault finding

Commissioning of the VFD

Follow chapter 1 in Vacon ‘Installation, Technical
and Maintenance Manual’. Fill in this check-list.

 Check that both the frequency converter and the motor are
grounded.
 Check that the mains and motor cables comply with the
requirements given in chapter 5 (Vacon manual)
 Check that the control cables are located as far as possible
from the power cables.
 Check that the shields of the shielded cables are connected
to protective earth marking.
 Check the tightening torques of all terminals.
 Check that the wires do not touch the electrical components
of the drive.
 Check that the common inputs of digital input groups are
connected to +24V or ground of the I/O terminal.
 Check the quality and quantity of cooling air.
 Check the inside of the frequency converter for
condensation.
 Check that all Start/Stop switches connected to the I/O
terminals are in the Stop-position
 Before connecting the frequency converter mains: Check
mounting and condition of all fuses and other protective
devices.
 Run the Startup Wizard (see the Vacon Application Manual)

Environmental Limits and Installing the

VACON 100X
The VACON 100X technical data can be found
in section 7.3 in Vacon ‘Installation, Technical
and Maintenance Manual’.

Mounting
Refer to chapter 3 in Vacon ‘Installation,
Technical and Maintenance Manual’.

Cable Connections
Refer to chapter 4 in Vacon ‘Installation,
Technical and Maintenance Manual’.
Note! The Vacon 100X is equipped with
an integrated mains switch. Please refer to
Vacon document DPD00978B for installation
instructions.

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6 Maintenance and fault finding

EMC Requirements

EMC levels
2nd environmental
Cable type
Category C3
Mains cable 1
Motor cable 2
Control cable 4
Cable types required to meet standards.

1 = Power cables intended for fixed installation and the specific mains voltage. Shielded cable not
required. (MCMK or similar recommended)
2 = Symmetrical power cable equipped with concentric protection wire and intended for the specific
mains voltage. (MCMK or similar recommended). See figure below.
3 = Symmetrical power cable equipped with compact low-impedance shield and intended for the
specific mains voltage. (MCCMK, EMCMK or similar recommended;
Recommended cable transfer impedance (1...30MHz max. 100 mOhm/m). See figure below.
*360° earthing of the shield with cable glands in motor end needed for EMC level C2.

4 = Screened cable equipped with compact low-impedance shield (JAMAK, SAB/ÖZCuY-O

or similar).

A
A B C
G1108711

A. Shield
B. PE conductor
C. PE conductors

Note: The EMC requirements are fulfilled at factory defaults of switching frequencies (all
frames).
Note: It safety switch is connected the EMC protection shall be continuous over the whole
cable installation.

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6 Maintenance and fault finding

Circuit breakers
Please disconnect the drive via an external
circuit breaker. You have to provide a switching
device between supply and main connection
terminals.

When connecting the input terminals to the

power supply using a circuit breaker, observe
that this is of type B or type C and ensure it has
a capacity of 1.5 to 2 times of the inverter’s
rated current.

NOTE: Circuit breaker is not allowed in

installations where C-UL is required. Only fuses
are recommended.

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6 Maintenance and fault finding

Cable and fuse sizes - CE-version (frame

MM4)
The recommended fuse types are gG/gL (IEC
60269–1) or class T (UL & CSA). The fuse
voltage rating should be selected according to
the supply network. The final selection should
be made according to local regulations, cable
installation conditions and cable specification.
Bigger fuses than those recommended below
shall not be used.

Check that the fuse operating time is less than

0.4 seconds. Operating time depends on used
fuse type and impedance of the supply circuit.
Consult the factory about faster fuses. VACON®
also recommends high speed J (UL & CSA),
aR (UL recognized, IEC 60269-4) and gS (IEC
60269-4) fuse ranges.

Purevent Single

Mains Terminal cable

Fuse and mo- size
Frame Type Iinput [A] (gG/gL) tor ca- Main Earth
[A] ble Cu [ terminal terminal
mm2] [mm2] [mm2]
0007 2 - 6.0 - 7.2 0.5 - 10 M4 ring
0008 2 3x1.5+ solid terminal
MM4 10
0005 4 - 5.4 - 8.1 1.5 0.5 - 6 or 1-6
0008 4 stranded

Purevent Twin

Mains Terminal cable

Fuse and mo- size
Frame Type Iinput [A] (gG/gL) tor ca- Main Earth
[A] ble Cu [ terminal terminal
mm2] [mm2] [mm2]
0011 2 - 9.7 - 10.9 0.5 - 10 M4 ring
0012 2 3x2.5+ solid terminal
MM4 16
0009 4 - 9.3 - 11.3 2.5 0.5 - 6 or 1-6
0012 4 stranded

The terminal sizes are intended for 1 conductor.

The cable dimensioning is based on the criteria
of the international standard IEC60364-5-52:
Cables must be PVC-isolated; Max. number of
parallel cables is 9.

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6 Maintenance and fault finding

When using cables in parallel, NOTE

HOWEVER that the requirements of both the
cross-section area and the max. number of
cables must be observed.
For important information on the requirements
of the earthing conductor, see chapter Earthing
and earth fault protection of the standard.
For the correction factors for each temperature,
see International standard IEC60364-5-52.

Note! PureVent Twin need 2.5mm² supply cable

but 1.5mm² for each motor cable, since each
motor is supervised via Thermistor in motor.

35
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6 Maintenance and fault finding

Cable and fuse sizes - UL-version (frame

MM4)
Purevent Single

Mains Terminal cable

Fuse
and size
Frame Type Iinput [A] (class T)
motor Main Earth
[A]
cable Cu terminal terminal
0007 2 - 6.0 - 7.2 AWG17-
0008 2 AWG24- AWG10
MM4 0005 4 - 5.4 - 8.1 10 AWG14
AWG10 M4 ring
0008 4 terminal

Purevent Twin

Mains Terminal cable

Fuse
and size
Frame Type Iinput [A] (class T)
motor Main Earth
[A]
cable Cu terminal terminal
0012 2 10.9 AWG17-
0012 4 11.3 AWG24- AWG10
MM4 20 AWG14
AWG10 M4 ring
terminal

The cable dimensioning is based on the criteria

of the Underwriters’ Laboratories UL508C:
Cables must be PVC-isolated; Max. ambient
temperature +40 °C (104 °F), max. temperature
of cable surface +70/+75 °C (158/167 °F); Use
only cables with concentric copper shield; Max.
number of parallel cables is 9.

When using cables in parallel, NOTE

HOWEVER that the requirements of both the
cross-section area and the max. number of
cables must be observed.
For important information on the requirements
of the earthing conductor, see standard
Underwriters’ Laboratories UL508C.
For the correction factors for each temperature,
see instructions of standard Underwriters’
Laboratories UL508C.

Note! PureVent Twin need AWG14 supply cable

and for each motor cable, since each motor is
supervised via Thermistor in motor.

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6 Maintenance and fault finding

Maintenance & reforming of capacitors.

See chapter 6.4 in Vacon ‘Installation, Technical
and Maintenance Manual’.

Floating Network
If your supply network is an IT (impedance-
grounded) system but your AC drive is
EMC-protected according to class C1 or C2 you
need to modify the EMC protection of the AC
drive to EMC-level T(C4).
This is done by removing the EMC screws as
described below:

NOTE

Failure to do so may cause danger or damage the unit!

EMC
EMC

EMC

G1108761

EMC screws on frame size MM4

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6 Maintenance and fault finding

6.2.1.1 Faults/Alarms

Fault finding.
If a fault occurs and the separator stops,
examine the cause of the fault.
Perform the actions described in the instruction
below to reset the fault.

1. Press and hold the Reset button for 1

second on the keypad or by entering the
Diagnostics Menu (M4).
2. In the submenu choose Reset faults (M4.2)
3. Select the Reset faults parameter.

G1108721

Diagnostic menu with graphical keypad.

Fault history

In Submenu Fault history (M4.3) you will find the

maximum number of 40 occurred faults.
For each fault in the memory you will also find
additional information, see below.

G1108731

Fault history menu with graphical keypad.

For further information, see chapter 10 in Vacon

‘Vacon 100 Application Manual’.

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6 Maintenance and fault finding

6.2.1.2 Choose Remote/Local control

Change of control place from Remote to Local

(Keypad).

1. Anywhere in the menu structure, push the

FUNCT-button.

2. Push the Arrow up or the Arrow down

button to select Local/Remote and confirm
with the OK-button.

3. On the next display, select Local or Remote

and again confirm with the OK button.

4. The display will return to the same location

as it was when the FUNCT-button was
pushed. However, if the Remote control
place was changed to Local (Keypad) you
will be prompted for keypad reference.

G1108741

Changing Remote/Local control

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6 Maintenance and fault finding

6.2.1.3 Access the control page

The Control page is meant for easy operation

and monitoring of the most essential values.

1. Anywhere in the menu structure, push the

FUNCT-button.

2. Push the Arrow up or the Arrow down

button to select Control page and confirm
with the OK-button.

3. The control page appears.

If keypad control place and keypad reference

are selected to be used you can set the Keypad
Reference after having pressed the OK-button.
If other control places or reference values are
used the display will show Frequency reference
which is not editable.
The other values on the page are Multi
monitoring values.

G1108751

Access Control page.

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6 Maintenance and fault finding

6.2.2 Replacing Frequency drive

Before doing any work on the frequency drive
make sure to shut down the separator and lock
the power switch in the "OFF" position.

Mount exchange drive

Unpack the new drive and make sure there is no
transportation damage.

NOTE

Remove EMC screw when connecting to ungrounded

(IT) power system. Otherwise the frequency converter
can be damaged.

After replacing the frequency drive, follow the

routines described before first start and start
in 5 Operating instructions on page 21. Pay
particular attention to how to verify direction of
rotation.

If the separator is running backwards, stop and

switch off the main switch and change place of
the power cables U/T1 and V/T2.

G0991081

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7 Technical references

7.1 Product description

Alfa Laval ref. 9011248 Rev. 4

Product specification: 881273-04-01

Type designation: CC200 Twin
Application: Removal of oil droplets and solid particles from crankcase
ventilation gas.
Directives & See 7.1.1 Declaration on page 44
Standards:

Technical design: Rotor made of aluminium and plastics.

The rotor is mounted on AC motor shaft.
Rigidly mounted bearings.
Exterior rubber buffers.
External frequency converter.
Restrictions: Max. flow: 400 m3/h per separator unit
Feed temperature: +20°C to +80°C
Ambient temperature at separator: +5°C to +60°C
Ambient temperature at control panel: +5°C to +60°C
This machinery is only allowed to be installed and operated in a
non-explosive atmosphere.
The machine is designed to allow an explosive atmosphere inside the
machine corresponding to Zone 1.
Risk for corrosion and erosion have to be investigated in each case
by the application centre.

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7 Technical references

7.1.1 Declaration

7.1.1.1 Purevent Twin

Alfa Laval ref. 9017986 Rev. 0

Supplier: ......................................................................................................................
Supplier address: ......................................................................................................................
Separator type: ................................................................................
Product specification: ................................................................................
Configuration number: ................................................................................
Serial number: ................................................................................

Declaration of Conformity
The machinery complies with the following Directives:

Designation Description
2006/42/EC Machinery Directive
2004/108/EC Electromagnetic Compatibility Directive
94/9/EC Atex Directive
The machinery is classified to category 2 for use in non-explosive
atmosphere and module; Internal control of production has been applied.
Design code: Ex II 2 /- G c IIB T1 X

To meet the requirements the following standards have been applied:

EN 60204-1 Safety of machinery - Electrical equipment of machines. Part 1: General

requirements
EN ISO 12100 Safety of machinery - General principles for design - Risk assessment
and risk reduction
EN 1127-1 Explosive atmospheres - Explosion prevention and protection - Part 1:
Basic concepts and methodology
EN 13463-1 Non-electrical equipment for use in potentially explosive atmospheres -
Part 1: Basic method and requirements
EN 13463-5 Non-electrical equipment intended for use in potentially explosive
atmospheres - Part 5: Protection by constructional safety 'c'
ISO 3744 Acoustics - Determination of sound power levels of noise sources using
sound pressure

The following electrical components used in the separator are approved according to the following
nationally recognized testing laboratories (NRTLs):

Designation Description
Electric Motor (WEG) 1kW 2P 90S/L WAF 1 CSA/UL
Variable Frequency VACON 100-3L-0012- CULUS
Drive (Vacon 100 AC 4-X (5.5kW)
drive)

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7 Technical references

The technical construction file for the machinery is compiled and retained by the authorized
person Tomas Zetterling within the Product Centre for High Speed Separators, Alfa Laval Tumba
AB, SE-14780 Tumba Sweden. By reasoned request all relevant technical documentation will be
sent by post to national authorities.

Location: ................................................................................
Date: ................................................................................

Signature: ................................................................................
Name: ................................................................................
Title: ................................................................................

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7 Technical references

7.2 Technical data

Alfa Laval ref. 9017006 Rev. 1

Line frequency: 50 / 60 Hz
Motor power at 400 VAC, 120 Hz 1 kW
Rated current: 2,34 A
Motor speed, synchronous 120 Hz: 7200 r/min
Gear ratio: direct drive
Start time max.: 30 seconds
Stop time: 120 seconds
Sound power / uncertainty: 8,6 / 0,3 Bel(A)
Sound pressure / uncertainty: 72 / 3 dB(A)
Max vibration level: 20 mm/s
(10-1000 Hz, acc. to ISO 2954)
Nominal flow: 150 m3/h
Max. capacity: 400 m3/h
Max. gas temperature: 80 °C
Weight of separator: 45 kg

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7 Technical references

7.3 Basic size drawing

Alfa Laval ref. 9016751 Rev. 1

357 179,5 230

89

702,5
F

366,5
821
221

49
791a

28
E
D 189

114
11

791b

G 221

709

G1071921

D. Rotor rotation direction

E. Inlet
F. Outlet
G. VFD (Frequency converter)

All dimensions are nominal.

Reservation for individual deviations due to
tolerances.

Data for connections see Connection list.

All connections to be installed non-loaded and

flexible.

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7 Technical references

Recommended in and outlet connections:

C
G1071931

A. Flexible rubber hose

Recommended: Fluoro Lined Silicone hose
B. minimum 80 mm
C. minimum 90 mm

Dimension for straight connection, see

requirement B.
Dimension for bent connection, see
requirement C.

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7 Technical references

7.4 Connection list

Alfa Laval ref. 9011273 Rev. 3

Connection Description Requirements/limits

No.

Inlet Inlet for process gas. See Technical data

221 Outlet for heavy phase (oil). No counter pressure. The outlet
- Interface: must never be obstructed. Hose
must be connected with downward
gradient.
Outlet Outlet for clarified gas The gas to be discharged to open
air environment or rerouted to
engine air intake.
Crankcase gas shall be treated as
a potential explosive gas.

709 Electrical connection 3-phase power supply

791a Earth connection, frame Shall be connected to earth
connection on motor (791b) with
insulated copper conductor with the
area of 6 mm²
791b Earth connection, motor See 791a
821 Plugged connection Higher pressure than crankcase
(Used only at installation and pressure at all engine loads. Max.
maintenance) 15mbar.

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7 Technical references

7.5 Function Requirement Specification (FRS)

Alfa Laval ref. 9017729 Rev. 4

7.5.1 General
This is a Function Requirement Specification
(FRS) for the control of the PureVent.
The FRS is valid for the products 881273 03
(PureVent Single) and 881273 04 (PureVent
Twin).

This document gives information, requirements

and recommendations about operational
procedures and signal processing for safe and
reliable operation of the separator.

7.5.2 References
This Interface Description is one complementary
document to the separator. Other such
documents that contain necessary information
and are referred to here are:

• Basic size drawing

• Connection List
• Connection Diagram
• Technical Data
• VFD instructions
• Y-connection motor

Standards referred to are:

2006/42/EC Machinery Directive

2006/95/EC Low Voltage Directive
2004/108/EC Electromagnetic Compatibility Directive

EN ISO 12100 Safety of machinery - General principles for design - Risk assessment
and risk reduction.
EN 60204-1 Safety of machinery - Electrical equipment of machines - Part 1 : general
requirements.
EN 61439-1/3/4 Low-voltage switchgear and controlgear assemblies - Part 1: General
rules
EN 61000 6-2 Electromagnetic compatibility (EMC) - Part 6-2 : generic
standards-Immunity for industrial environments.
EN 61000 6-4 Electromagnetic compatibility (EMC)-Part 6-4 : generic standards -
Emission standard for industrial environments.
EN 12547 Centrifuges – Common safety requirements.

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7 Technical references

7.5.3 Definitions
For the purpose of this document, the following
definitions apply:

• Set speed: Default set to 120Hz in VFD to

match motor speed of 7200 rpm to reach
optimal separation.

7.5.4 Description of operation

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 the
documents listed under References
• The separator control system is activated.

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7 Technical references

If above conditions are not fulfilled the separator

is not ready for operation. The following
operation modes are defined:

A B

C E

D
*

F
G
H
I
G1110011

A. Power on F. Automatic transition

B. Standstill G. Transition on alarm
C. Start H. Local command
D. Production I. Remote command
E. Stop *. Local Stop command active in remote operation

7.5.4.1 Power on/Stand still

At STAND STILL mode the power to the

separator motor is off and the rotor is not
rotating.

7.5.4.2 Start

At power on the power to the separator motor

is on and the rotor is rotating and accelerating
up to set speed (120 Hz).

It is possible to Start the separator from both

Stand still and Stop mode.
Flying start is possible, i.e. the VFD catches
the actual speed without having to start from
standstill and accelerates up to set value.

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7 Technical references

The PureVent separator could be started with or

without crankcase gases in the system.

Start sequence can be aborted at any time if the

operator pushes Stop.

7.5.4.3 Production

The power to the separator is on and the rotor is

rotating at set speed.
The PureVent separator could be in Production,
with or without crankcase gases in the system.

7.5.4.4 Stop

At Stop mode the power to the separator motor

is off and the rotor is rotating and coasting. Stop
can be activated either through local or remote
command (release of start signal), or through
alarm triggering.
Note. Local Stop command is also active in
remote operation.

7.5.5 Alarms
Alarm conditions, in which mode they are active
and what action to take is described in below
table:

Alarm STOP START PRODUC- STANDBY Auto reset Description

TION
Input Phase Not active To STOP To STOP To STOP X Check supply
Fault cable and
fuses.
Undervoltage Not active To STOP To STOP To STOP X Check supply
Fault voltage.
Output Not active To STOP To STOP To STOP Check motor
Phase Fault cable and
motor.
Thermistor Not active To STOP To STOP To STOP Check motor
Fault cooling.
Earth Fault Not active To STOP To STOP To STOP Check
grounding of
motor and
VFD.

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7 Technical references

7.5.6 Parameters
Additional information see 6.2.1 Instructions for
VACON 100X on page 30 and 7.2 Technical
data on page 46.
Range, default value and conditions on all
parameters are described in below tables.

7.5.6.1 Frequency drive (VFD)

START-UP DATA
Parameter Single Value Twin Value Note
Motor nominal 400 V 400 V From motor
Voltage name plate
Motor nominal 120 Hz 120 Hz From motor
Freq. name plate
Motor nominal 7080 rpm 7080 rpm From motor
Speed name plate
Motor nominal 2.34 4.68 From motor
Current name plate
Motor nominal 0.85 0.85 From motor
Cos Phi name plate
Motor nominal 1 kW 2 kW From motor
Power name plate

START/STOP/DIR
Via digital input

LIMITS
Maximum current In+10%
Overvoltage control Active
Undervoltage control Active
Minimum Freq. Ref. 120 Hz
Maximum Freq. Ref. 120 Hz

START/STOP
Keypad stop button Always active
Start Function Flying start
Stop Function Coast

ACCEL/DECEL
Acceleration Time 15s

AUTOMATIC RESET
Automatic Reset Enabled
Wait Time 1s

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7 Technical references

Trial Time 60 s
Number of Trials 3
AR Undervoltage Yes
AR Overvoltage Yes
AR Overcurrent Yes
AR Unit Overtemp No
AR Motor Overtemp No

RELAY OUTPUTS
Relay Output 1 Fault
Relay Output 2 Run

PROHIBIT FREQUENCIES
Low 45Hz
High 62Hz

SYSTEM CONTROLS
User Level Control Monitoring

PROTECTION SETTINGS
Input Phase Fault 3-phase support
Output Phase Fault Fault (Stop by Coasting)
Thermistor Fault Fault (Stop by Coasting)

MOTOR THERMAL Single Twin

PROTECTION
Motor Thermal 2=Fault 0=No action
Protection

7.5.7 Additional functions

• Hours counter
• Active faults, displayed in VFD.
• Alarm history
• External alarm indication. Relay 1 on the
VFD is active during non-fault state on the
VFD.
• External running indication. Relay 2 on the
VFD is active during run-state on the VFD.

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7.5.8 Handling of connection

interfaces

7.5.8.1 Electrical connections

701 Separator motor

The separator is equipped with a 3-phase motor.
The motor is fed from a frequency converter.

709 Electrical connection

The frequency converter is fed from 3-phase
power supply.

791 Grounding
A grounding cable is connected between 791a
on the frame and 791b on the motor.

7.5.8.2 Gas in- and outlet connections

Avoid sharp bends and use the same diameter

on all pipes to avoid to high pressure drop.

- recommended diameter on the inlet

minimum 4" (100mm)
- recommended diameter on the outlet
minimum 3" (75mm)
- At low gas flows it is possible to use smaller
pipe dimensions.

The pipes should be as straight as possible to

lessen pressure drop.

It is recommended to make the piping with

a slope of minimum 3° upwards in the flow
direction so that oil cannot accumulate and
hinder the gas flow or create a liquid lock.

B
Min 3°

X
D

G1040451

G1040411

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7 Technical references

A bypass tube of minimum 3" (75mm) is

recommended to be installed between the inlet
pipe and the outlet pipe.

Alternatively, an import pipe of minimum 3"

(75mm) can be installed to the inlet pipe from
the ambient air.

This is a precautionary measure:

- to protect the crankcase from low pressure

at different engine loads.
- in case of PureVent failure.
- if occasional increase of crankcase gas
flow occurs.

The gas flow should be adjusted to the engine

size with a throttle valve at full engine load to
get the desired crankcase pressure at maximum
blow-by flow. The valve should be placed on the
inlet of PureVent and after the bypass or after
the import pipe.

Due to wear of the diesel/gas engine parts, the

gas flow will slightly increase with time, which
can result in a slight increase of the crankcase
pressure. If this is a problem, an adjustment of
the inlet valve during the service period may be
necessary.

7.5.8.3 Oil outlet 221

PureVent has to be placed above the returned

oil location, with an inclined hose or pipe all the
way between PureVent and the crankcase. The
oil drain should be installed in such way that
there is no risk for liquid lock.

A badly designed or installed return hose/pipe

on the oil outlet could stop the flow of oil.
There has to be a small gas flow through the
oil outlet so that the separated oil can exit from X
PureVent.

The pressure inside PureVent at the oil outlet

has to be higher than the pressure to where the
oil will be drained.
G1040471
X
It is important to check that oil exits at all engine
loads.

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7 Technical references

7.5.8.4 PureVent pump capacity

PureVent functions as an air pump with a

capacity of 700 m3/h and can create a negative
pressure of 32 mbar if the system is built without
flow resistant piping. There should be no other
pressure regulating devices in conjunction with
PureVent. If there is an existing installation with
an eductor, this should not be included in the
installation.

7.5.9 Installation

7.5.9.1 Mounting

The PureVent should never be mounted directly

on the engine.
The PureVent is mounted on 4 rubber vibrations
isolators to protect the separator from internal
and external vibrations.

Piping to PureVent must be connected with

flexible hoses. The flexibility of the hoses affects
the lifetime of the motor bearings.

7.5.9.2 Open or closed system

In an open system the cleaned gas is evacuated

to the open air where it is close to atmospheric
pressure.
In a closed system the cleaned gas is fed back
to the air inlet of the diesel/gas engine where
the pressure is much lower than atmospheric.
Some installations require a positive crankcase
pressure and some a negative crankcase
pressure.

7.5.9.3 Twin PureVent

A twin PureVent installation is required if the

blow-by flow is too high for one PureVent, or a
higher separation efficiency is needed.

It is important that the piping to both the

PureVents is symmetrical and preferably with
Y-pipes so that the flow through them is equal.
An import pipe or a bypass pipe can be installed
for a more constant crankcase pressure at
varying engine loads.

Both PureVents are driven by one common VFD.

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7 Technical references

7.5.9.4 Installation guide

For an open system with an import pipe see page 60.

For an open system with bypass pipe see page 65.

For a closed system see page 70.

Make sure to measure the pressure for

connection 821 according to Connection list on
page 49.

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7.5.9.5 Open system

Open ventilation system with a negative

or atmospheric crankcase pressure, with
import pipe
In an open system and if the crankcase pressure
should be negative or close to atmospheric, an
import pipe from ambient air can be used.

5
P
V

2
3

X026987B

1. Import pipe 4. Crankcase

2. Inlet valve 5. Turbo
3. Oil outlet

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Open ventilation system with a positive

crankcase pressure, with import pipe
If the desired crankcase pressure should be
positive, an extra adjustable valve is needed
and the two inlet valves should be adjusted for
proper function.

5
P
V

2
3

4
6
X026988B

1. Import pipe 4. Crankcase

2. Inlet valve 5. Turbo
3. Oil outlet 6. Extra inlet valve

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Adjustment of the throttle valve with

diesel-/gas engine at full load.
1. Let the diesel/gas engine run at 100 %
output.

2. Start PureVent with the inlet valve open and

wait until it reaches full speed (120 Hz).

3. Adjust the inlet valve until the desired

crankcase pressure is reached. Check that
a small flow of air is going in through the
import pipe. If not, open the valve a little
more.

4. Lock the inlet valve to prevent accidental

adjustment.

5. It may be necessary to adjust the valve

later when the engine starts to wear and
the blow by flow increases.

5
P
V

2
3

X026989B

The arrows indicate the flow direction at full load

1. Import pipe 4. Crankcase

2. Inlet valve 5. Turbo
3. Oil outlet

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Part load conditions.

If we assume that the engine produces 180 m3/h
blowby gases at full load and 70 m3/h blowby
gases at part load. PureVent will then create
a pressure which is too low in the crankcase.
This is avoided by using an import pipe for
import of some flow of air. About 110 m3/h (red
arrows in illustration) will automatically start
to flow through the import pipe. This will not
significantly affect the pressure in the crankcase.

5
P
V

2
3

X026990B

The arrows indicate the flow direction at part load conditions

1. Import pipe 4. Crankcase

2. Inlet valve 5. Turbo
3. Oil outlet

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If for some reason PureVent stops rotating,

uncleaned gases will exit through the import
pipe. (Without the pipe the crankcase pressure
will increase somewhat because of the flow
resistance through PureVent.)

5
P
V

2
3

X026991B

The arrows indicate the flow direction if PureVent stops running

1. Import pipe 4. Crankcase

2. Inlet valve 5. Turbo
3. Oil outlet

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7.5.9.6 Open system with bypass pipe

Open ventilation system with a negative

or atmospheric crankcase pressure, with
bypass pipe.

5
P
V

2
3

4
6
X026992B

1. Bypass pipe 4. Crankcase

2. Inlet valve 5. Turbo
3. Oil outlet 6. Coupling

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If the desired crankcase pressure should be

positive, an extra adjustable valve is needed
and this inlet valve (6) should be adjusted for
proper function.

1
5
P
V

2
3

7 4
6
X026993B

1. Bypass pipe 5. Turbo

2. Inlet valve 6. Extra inlet valve
3. Oil outlet 7. Coupling
4. Crankcase

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Adjustments of the throttle at full load of the

diesel/gas engine
1. Let the diesel/gas engine run at 100%
output.

2. Start PureVent with the inlet valve open

and wait until it reaches full speed (120Hz).

3. Open the bypass coupling.

The bypass pipe with coupling is used for
tuning the function of the PureVent.
A coupling with a flexible hose (alt. an
inspection cover) is recommended to
facilitate visual smoke detection. Cover the
end against the PureVent gas outlet.

4. Close the inlet valve in small steps until

visible smoke starts to emerge through the
opening against the PureVent inlet.

5. From this position, open the inlet valve

2-3 degrees. Check that no visible gas is
coming out from the lower bypass pipe.

6. Lock the inlet valve to prevent accidental

adjustment.

7. Reconnect the bypass coupling.

1
5
P
V

2
3

6 4

X026994B

The arrows indicate the flow direction at full load conditions

1. Bypass pipe 4. Crankcase

2. Inlet valve 5. Turbo
3. Oil outlet 6. Coupling

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Part load conditions

If we assume that the engine produces 150 m3/h
at full load and 30 m3/h blowby at idle, PureVent
will then create a pressure in the crankcase
during part load conditions which will be too low.
This is avoided by using the bypass pipe for
recirculation of some gas.

About 120 m3/h of the purified gases (red

arrows in illustration) will automatically start to
flow through the bypass pipe for recirculation.

1
5
P
V

2
3

6 4

X026995B

The arrows indicate the flow direction at idle conditions

1. Bypass pipe 4. Crankcase

2. Inlet valve 5. Turbo
3. Oil outlet 6. Coupling

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7 Technical references

If PureVent for some reason stops rotating,

uncleaned gases will exit through the bypass
pipe. (Without the pipe the crankcase pressure
will increase somewhat because of the flow
resistance through PureVent.)

1
5
P
V

2
3

6 4

X026996B

The arrows indicate the flow direction if PureVent stops running

1. Bypass pipe 4. Crankcase

2. Inlet valve 5. Turbo
3. Oil outlet 6. Coupling

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7 Technical references

7.5.9.7 Closed system

In a closed system the cleaned gas is fed back

to the turbo air inlet of the diesel/gas engine
where the gas pressure is negative (below
atmospheric).

The pressure may be very low at the point

where the cleaned gas from Purevent outlet is
connected, (P3).

The pressure at P3 will affect the pressure

inside PureVent, position (P2). If the pressure
in the crankcase, position (P1) is higher than in
PureVent, position (P2) the oil will not drain out
and there may even be a backflow of air or oil
up through the oil drain.

By adding an adjustable outlet valve, the

pressure inside PureVent will be higher because
of the pressure drop over the outlet valve. The
pressure P2 can be checked by measuring the
pressure on the oil outlet. This should be higher
than the crankcase pressure P1.

1 6
P
P3
V
P2 5

2
3

P1
X026997B

1. Import pipe 4. Crankcase

2. Inlet valve 5. Turbo
3. Oil outlet 6. Outlet valve

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7 Technical references

Adjustments of the throttle at full load of the

diesel/gas engine
1. Let the diesel/gas engine run at 100%
output.

2. Start PureVent with the inlet valve open and

wait until it reaches full speed (120 Hz).

3. Adjust the inlet valve and outlet valve until

you reach the desired crankcase pressure
and a higher pressure at P2 than at P1.
Check that a small flow of air enters in
through the import pipe. If not, open the
valve a little more.

4. Lock the valves to prevent accidental

adjustment

5. It may be necessary to adjust the valve

later on as with time the engine starts to
wear and the blow by flow increases.

1 6
P
P3
V
P2 5

2
3

P1
X026998B

The arrows indicate the flow direction at full load conditions

1. Import pipe 4. Crankcase

2. Inlet valve 5. Turbo
3. Oil outlet 6. Outlet valve

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7 Technical references

Part load conditions

If we assume that the engine produces 150 m3/h
at full load conditions and 60 m3/h blowby at part
load, PureVent will then create a pressure in the
crankcase which is too low. This can be avoided
by using an import pipe for import of some flow
of air. About 90 m3/h (red arrows in illustration)
will automatically start to flow through the
import pipe. This will not significantly affect the
pressure in the crankcase.

1
6
P
P3
V
P2 5

2
3

P1
X026999B

The arrows indicate the flow direction at part load conditions

1. Import pipe 4. Crankcase

2. Inlet valve 5. Turbo
3. Oil outlet 6. Outlet valve

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7 Technical references

If PureVent for some reason stops rotating

uncleaned gases will go out through the import
pipe. (Without the pipe the crankcase pressure
will increase because of the flow resistance
through PureVent.)

1 6
P
P3
V
5
P2
2
3

P1
X027000B

The arrows indicate the flow direction if PureVent stops running

1. Import pipe 4. Crankcase

2. Inlet valve 5. Turbo
3. Oil outlet 6. Outlet valve

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7 Technical references

7.6 Set of tools

Alfa Laval ref. 578323 Rev. 0

Lifting eye

G1109821

Nut
G1109831

Air hose nipple

G1109841

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7 Technical references

7.7 Motor data

For information regarding motor specifications,
see motor plate.

NOTE

For complete information about motor variants, please

contact your Alfa Laval representative.

7.7.1 Y-connect motor (400 V)

Alfa Laval ref. 9016911 Rev. 0

This unit must be Y-connected.

W2 U2 V2
U1 V1 W1

L1 L2 L3

G1002641

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7 Technical references

7.8 Lifting instructions

Alfa Laval ref. 9018149 Rev. 0

A B C

D E F
G0968441

A. Lifting the complete separator

B. Lifting the complete frame
C. Lifting the rotor
D. Weight to lift: 45 kg
E. Weight to lift: 19 kg
F. Weight to lift: 26 kg

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7 Technical references

7.9 Connection diagram

VFD Twin
Alfa Laval ref. 9016915 Rev. 1

A
L1 L2 L3 PE
B C
D
NO

M
U1 PE 24VOUT DI1
EMC EMC
*** 1 3 5
6 8

2 4 6

L1 L2 L3

E H I
1xRO
* 1xRO
*
G
F TI+ TI-
U/T1 V/T2 W/T3 28 29 21 22 23 24 25 26
PE PES RO1/1 RO1/2 RO1/3 RO2/1 RO2/2 RO2/3

K L

1 3 5 1 3 5
** -Q1 ** -Q2
2 4 6 2 4 6

M M
-M1 3~ -M2 3~
Θ Θ

J
G1104511

A. Power supply
3x380 - 480VAC
B. 24 VDC Supply for inputs
C. 1-Engine running
D. External
E. Supply
F. Motor
G. Thermistor
H. Relay output 1
I. Relay output 2
J. Thermistor
K. Relay 1
VFD Fault
L. Relay 2
VFD Running
M. NOTE!
Remove EMC screws (2 pcs) when connecting to ungrounded (IT) power system.
EMC protection will not be fulfilled.
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7 Technical references

The recommended fuse types are gG/gL (IEC 60269-1) or class T (UL & CSA). The fuse voltage
rating should be selected according to the supply network.
The final selection should be made according to local regulations, cable installation conditions and
cable specification.
Bigger fuses than those recommended below shall not be used

* Switching capacity
24VDC/8A
250VAC/8A
125VDC/0.4A
Min.switching load 5V/10mA
** NOTE:
If safety switch is connected the EMC protection shall be
continuous over the whole cable installation.
*** Integrated safety switch in VFD.
To be used during maintenace.

NOTE

Branch circuit protection to be provided by installer.

For fuse and cable sizes, please see VFD instruction.
External cables are not included in Alfa Laval delivery.
Max length of motor cable is 50m.
Minimum cable area 2.5mm2 for supply cable to VFD
Minimum cable area 1.5mm2 to motors
Use tri-symetric shielded motor cable.

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7 Technical references

7.10 Machine plates and safety labels

Alfa Laval ref. 9015715 Rev. 0

G09925H1

1. Machine plate

3. Name plate

5. Safety label ! WARNING

Read the instruction manual before installation, Read the instruction

manuals before

operation and maintenance. Consider installation, operation

and maintenance.
Consider inspection
intervals.
Separator must stop
rotating before any

inspection intervals. Failure to strictly follow

instructions can lead to
fatal injury.
dismantling work is
started.

9017573-02-V0

Failure to strictly follow instructions can lead to

fatal injury

If excessive vibration occurs, stop separator.

Separator must stop rotating before any

dismantling work is started.

6. Plate with arrow. Direction of rotation

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8 Installation

8.1 General information

8.1.1 Connections
Gas inlet at the bottom “A”
(ø 114 mm, hose clamp)

Gas outlet in the top “B”

(ø 89 mm, hose clamp)

Oil outlet at the bottom “C”

(ø 11 mm, hose clamp)

Electrical supply to frequency converter 3x400 V.

Check for correct direction of separator rotation B
by checking that the direction of the motor fan is
clockwise seen from top.

NOTE

Make sure grounding cable is connected between the

motor and the frame, see 7.4 Connection list.

A
G0968331

NOTE

Remove EMC screw when connecting to ungrounded

(IT) power system. Otherwise the frequency converter
can be damaged.

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8 Installation

After replacing the frequency drive, follow the

routines described before first start and start
in 5 Operating instructions on page 21. Pay
particular attention to how to verify direction of
rotation.

If the separator is running backwards, stop and

switch off the main switch and change place of
the power cables U/T1 and V/T2.

G0991081

It is recommended to install the PureVent as far

away from the engine as possible. In any case
it must never be mounted directly on the engine,
due to vibrations. Measure the gas temperature
to make sure that it does not exceed 80°C.

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8 Installation

8.1.2 Foundation drawing

Alfa Laval ref. 9017050 Rev. 1

200 min.
1000

200 min.

1200
D
1450 min.

A
1200

C E

8
342

90°

B
4x 9 M8

180min. 240

I J G F
G1071941

A. Center of gravity, complete machine

B. Horizontal max. deviation: 3°
C. Max. height of largest component including lifting tool
D. Service side
E. Recommended free floor space
F. Foundation plate
G. Center of lifting device
H. Min. lifting capacity: 50 kg
I. Dynamic force (static forces excluded) from separator do not exceed:
Vertical: ±6 kN/foot
Horizontal: ±6 kN/foot
J. Total foundation force (sum of all feet):
Vertical: ±6 kN
Horizontal: ±6 kN

PureVent has 4 rubber isolators with threaded

holes (M8) at the bottom, These rubber isolators
must be used between the unit and the bracket.
See foundation drawing above for details.

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8 Installation

8.2 Installation
PureVent can be installed in different ways.
This is because conditions and requirements
may vary. In chapter7.5 Function Requirement
Specification (FRS) on page 50, instructions and
proposals are given on how to install PureVent B
and how to adjust the gas flow to PureVent. Min 3°

The simplest installation of PureVent consists of

an inlet with an adjustable valve and an outlet
to the ambient air (open system), see figure. C
This setup can be used if the diesel/gas engine
is running at full load most of the time and if a D
lower crankcase pressure during start and stop
is acceptable.
A
If the engine runs at lower loads and idling,
PureVent will then pump a lower pressure into
the crankcase through the inlet valve set at full G1040451

load.

If a more constant crankcase pressure at all

engine loads is desired, the installation can be
complemented with an import pipe from the
surrounding air or with a bypass pipe between
PureVent inlet and outlet.

VFD unit
Position the VFD control unit in such a way that
the operator is not subjected to any hazardous
work environment.

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8 Installation

8.3 Storage and transport of goods

8.3.1 Storage
Specification
Upon arrival to the store, check all components
and keep them:

• well stored and protected from mechanical

damages.
• dry and dust free air and protected from
rain and humidity.
• The rotor is delivered in a VCI-bag, store
the rotor in the bag as protection from
corrosion.

For outdoor installation the separator unit should

be started up and run for 5 minutes once every
other week, in case the Diesel Engines are out
of use for long time.

8.3.2 Transport
specification
• The separator must always be tied properly
with the lifting-rope when it is being lifted.
See 7.8 Lifting instructions on page 76.
• During installation, all inlets and outlets on
the separator and its accessories must be
covered to be protected from dirt and dust.

NG
WARNI
!
Crush hazards
Use correct lifting tools and follow lifting instructions.

Do not work under hanging load.

8.3.3 Transport of goods

The separator is transported unassembled with
the three parts (Frame complete, Rotor with
motor and VFD-unit). For assembly see 6.1.2
Every 16 000 hours of operation on page 26.

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8 Installation
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9 Spare parts
Item Qty Part No. Denomination
2 578628-16 Service kit Rotor
-including disc stack, drive and electric motor assembled
2 578628-17 Service kit Isolators
-including Isolators
1 578628-19 Service kit frequency converter
-including frequency converter
2 578628-15 Service kit O-rings
-including O-rings
VFD spare parts
1 1 9016921-03 Internal fan 2 4

2 1 9016921-04 External fan

3 1 9016921-05 Safety breaker

4 1 9016921-06 Operator panel 1

3
G1109911

87