R01 - 4420 0024 001 PDF

IOM Manual
Customer: Keppel Fels Ltd., Singapur
Project: Keppel Fels – B354 / B355 / B356 / B357 / B360 / B361
Document-No.: 4420-0024-001
1451.282.060 / 1451.282.062 / 1451.282.923
WS Order No.:
1451.282.929 / 1451.282.931 / 1451.282.936
engineering for a better world GEA Mechanical Equipment

2
Die Verfasser freuen sich immer über Kommentare und Ratschläge diese Dokumentation betreffend.
Sie können gesandt werden an
The authors are always grateful for comments and suggestions for improving the documentation. They
can be sent to
© GEA Westfalia Separator Group
If the drawings / documents are not approved / reviewed and re-submitted to GEA
Westfalia Separator within 10 working days, Westfalia will begin / continue production.
Subsequent modifications may delay delivery times and / or cause additional costs.
01 15.04.2014 As built 2321Ce 2152Hu
00 04.12.2013 Issued for information 2321Ce 2152Hu

Revision/
Date Description Created Checked Approved Client approval
Status
GEA Mechanical Equipment

GEA Westfalia Separator Group GmbH
Werner-Habig-Str. 1, 59302 Oelde, Germany
Tel.: +49 2522 77-0 · Fax +49 2522 77-2488
ws.info@geagroup.com,· www.westfalia-separator.com
GEA Westfalia Separator

Safety precautions
for plants
No.: 9001
Edition: 0712
Designation: Safety precautions

2 9001 / 0712 / Safety precautions / 25.07.2012
ORIGINAL INSTRUCTION
Subject to modification!
The authors are always grateful for comments and suggestions for improving the
documentation. They can be sent to

Tel.: +49 2522 77-0 · Fax +49 2522 77-2488
GEA Westfalia Separator Group

9001 / 0712 / Safety precautions / 25.07.2012 3
For your safety

• Strictly adhere to instructions marked with this symbol.
This avoids damage to the plant or plant components.
• Take special care when carrying out operations marked with this
symbol -
otherwise danger to life.
Note: • This symbol is not a safety precaution but rather a reference to infor-
mation which help to better understand the plant components and the
processes.
• Observe the accident prevention regulations!

The local safety and accident prevention regulations apply uncondi-
tionally to the operation of the plant. The plant operator must ensure
compliance with these regulations.
• Follow the instructions in the manual.

Follow only the instructions given in this manual.
Repair and maintenance work that goes beyond the scope described
in this manual may not be carried out.

1 Safety precautions
1.1 Safety markings ....................................................................................... 5

1.1.1 Safety markings and their meaning ......................................................... 5
1.2 Performing work on a plant ...................................................................... 8
1.2.1 Demands on the operating and maintenance personnel ......................... 8
1.2.2 Spare part requirements .......................................................................... 9
1.2.3 Electrical installation ................................................................................ 9
1.2.4 Before start-up ....................................................................................... 10
1.2.5 Start-up .................................................................................................. 11
1.2.6 Shut-down and »Emergency-Off« ......................................................... 13

1.1 Safety markings

The safety markings (adhesives and metal plates) are attached to all plants, on
the hood and frame of the respective plant component in such a way that they
are clearly visible.
All safety markings on the plant, control system and plant components must al-
ways be in perfect condition.
• Clean dirty safety markings.
• Replace damaged safety markings.
1.1.1 Safety markings and their meaning

The following safety markings must be attached to the monitoring system as
adhesive labels:
Be sure to adhere to the plant

documentation!
• Every person who is assigned the
task of installing, operating, main-
taining and repairing the plant must
have read and understood the doc-
umentation.
• The documentation must be com-
plete kept near to the installation
and be readily accessible to the op-
erators. It must be available to the
operators at all times!
Fig. 1
Disconnect power prior to start-

ing work!
Risk of injury due to electrical voltage
and unintended start-up of the plant!
Before carrying out work on the

plant and electrical plant compo-
nents:
• Make sure the plant is at a standstill.
• Switch off all electrical appliances
via the main switch,
• Lock the installation to prevent it
Fig. 2 from being accidentally switched on.

Frequency converter operation!

• When setting the frequency convert-
er, do not exceed the admissible
speed (see nameplate)!
Note:
This adhesive plate is only used for
frequency converter operation.
Fig. 3
Warning of extreme surface

temperatures!
The surfaces of the plant components

can be hot!
Note:
This adhesive plate is only used for hot
operation.
Fig. 4
Danger due to electrical current!

Non-compliance with the protective
measures can result in serious dam-
age to persons or property.
Before working on electrical com-

ponents:
CAUTION:
The parts marked in this way can
carry voltage even when the main
Fig. 5 switch is off!
• Lock the installation to prevent it from being accidentally switched on.

• Take adequate preventive measures according to the national orovisions (in
Germany in accordance with the rules and regulations of the VDE (Verein
Deutscher Elektriker / Association of German Electrical Engineers) or EVU
(Europäische Vereinigung für Unfallforschung und Unfallanalyse / European
Association for Accident Research and Analysis) institutions.
• The work may only be carried out by competent persons (qualified technical
specialists).

Potential equalisation (protec-

tive-earth terminal)
The grounding protection is a measure
which, in the case of a malfunction,
leads off the touch voltage into the
earth.
Fig. 6

1.2 Performing work on a plant
The plant works reliably, provided that

it is operated and maintained in ac-
cordance with our operating instruc-
tions.
Fig. 7
Special attention must be given to:

• assembly
• electrical installation
• before start-up
• start-up
• shut-down
• maintenance and repair
1.2.1 Demands on the operating and maintenance personnel

Operating, maintaining or repairing the plant requires specialized knowledge!
CAUTION!
Operating, maintenance or repair work by unqualified or unauthorized
personnel can lead to operating, assembly and handling errors and severe
damage to persons and property.
Westfalia Separator accepts no liability for damage caused by unqualified

or unauthorized personnel!
For operation, maintenance and repair work, personnel may only be deployed
who
• have reached a minimum age of 18 years.
• are demonstrably familiar with the state-of-the-art through briefings and train-
ing.
• are adequately qualified for performing the work and checking it.
Electrical work may only be carried out by an authorized electrician!
The operator of the plant

• is responsible for the necessary skills and knowledge of the personnel.
• is responsible for briefing and training the personnel.
• must be sure that the personnel have read and understood the manuals nec-
essary to carry out their work.

Westfalia Separator offers a an extensive range of training and advanced train-

ing courses. You can obtain further information from Westfalia Separator or from
one of the authorized representatives.
1.2.2 Spare part requirements
• Use only genuine spare parts from Westfalia

Separator.
The use of non-genuine parts leads to:
– safety risks,
– less durability and availability,
– increased service requirement.
If a safety risk occurs when using non-original
spare parts, this may have legal consequences
Fig. 8 for the responsible persons. In such cases,
Westfalia Separator accepts no liability or war-
ranty claims.
1.2.3 Electrical installation
• Electrical work may only be car-

ried out by an authorized electri-
cian!
• The governing accident prevention
regulations apply for the electrical
appliances and installations.
• Special attention must be paid to the
installation guidelines of Westfalia
Separator.
• The frequency and voltage of the
power supply must correspond to
the machine specifications.
Fig. 9
• Carry out voltage equalization.

• Observe legal regulations; e.g. in the EU:
– Low-voltage guideline 73/23/EWG
– Electro-magnetic compatibility 89/336/EWG.
– Guidelines of the classification societies.

1.2.4 Before start-up
• Check that the lubrication and cool-

ing systems are serviceable.
Fig. 10
• Check whether the supervisory

equipment is operational and the
correct limit values are adjusted.
• When hoods, concentrate collectors
and vessels are pressurized, e.g. by
– inert gas blanketing,
– cooling,
– steam sterilization etc.
the pressures stated on the boiler
plate must not be exceeded.
Fig. 11
• Check that the product lines are set

to operation.
• Regularly check hoses for signs of
ageing.
• Check sight glasses for mechanical
damage.
• Damaged parts must be replaced
immediately by new or reconditioned
parts.
Fig. 12

1.2.5 Start-up
• Wear ear protection.
Fig. 13
In case of frequency converter

operation:
• Do not under any circumstances
manipulate the frequency converter
to exceed the permissible speed
(see nameplate).
• The plant may only be operated with
an independent device for speed
limiting.
Fig. 14
• Do not feed product which is catego-

rised as explosive.
• Do not operate the equipment in ex-
plosion-hazarded areas.
Note:
This is except for plants equipped for
operation in explosion-hazarded areas.
Fig. 15

• The plant may be fed with inflam-

mable product only when being in-
ert-gas blanketed.
• The oxygen level has to be kept be-
low limit of inflammability by means
of an appropriate inert gas.
Fig. 16
• When processing products harmful

to persons, observe the pertinent
safety regulations.
• Refer to the safety data sheet of the
product.
• Wear protective clothing.
Fig. 17
Only in case of hot operation:

• Product-contacting parts such as
– pipes and hoses,
– components,
– vessels
o
reach temperatures over 80 C
o
(176 F).
Fig. 18

1.2.6 Shut-down and »Emergency-Off«
• For shut-down refer to the chapter

"Operation".
Fig. 19

Note
Notes
Notizen
Anotaciones
Для записей
Muistiinpanot
Σημειώσεις
Notater
Notes
Note


Tel.: +49 2522 77-0 · Fax +49 2522 77-2488
Qualification of staff
Edition: 0712
Designation: Qualification of staff

2 0712 / Qualification of staff
ORIGINAL INSTRUCTION
The authors are always grateful for comments and suggestions for improving the
documentation. They can be sent to

Tel.: +49 2522 77-0 · Fax +49 2522 77-2488

0712 / Qualification of staff 3
Qualification of staff
Work on / with separators requires special skills.

• Provide staff with special training / instruction for the following tasks:
– Operation,
– Maintenance,
– Repair.
• Clearly define responsibilities:
– Work performed by authorised persons only.
Type and source of danger:

Storage, transportation, erection, operation and maintenance of the sep-
arator / system by insufficiently trained staff.
Possible consequences of failure to observe:

Danger Incorrect operation, assembly and handling errors can cause serious damage,
injury / death.
Measures to prevent the danger:

– Use Westfalia Separator service.
– Take advantage of training opportunities.
– Read/follow operating manuals / operating instructions.
Westfalia Separator offers a comprehensive range of training measures.
The owner-operator is responsible for the training of staff.
NOTE
Contact Westfalia Separator or your nearest representative for more infor-

mation.
The owner-operator must select staff who, for example, fulfil the following re-
quirements:
• Minimum requirement:
– Read / understand the markings on the separator,
– Read / understand user instructions.
• Further requirements and skills:
– Basic general technical skills.
– Content of the operating manual / operating instruction.
– Measures for the prevention of accidents.
– Planning and implementation of installation.
– Securing of loads.
– Planning and implementation of start-up.
– Operation of the separator / system.
– Cleaning of the separator / system.
– Maintenance of the separator / system.
– Repair of the separator / system.
– Storage in case of extended periods of stoppage.

– Decommissioning of the separator / system.

– Disposal of operating material.
– Disposal of the separator / system.
• Other suitability:
– Only assign tasks to dependable persons.
– Minimum age of 18 years.
• Only employ persons undergoing training / apprenticeship under supervision.
The required skills and knowledge depend on the

tasks assigned.
NOTE
We reserve all rights to these documents. They may only be passed onto third parties after obtaining prior consent from Westfalia Separator Group GmbH.


Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note


Tel.: +49 2522 77-0 · Fax +49 2522 77-2488
Safety Precautions and User Instructions
for
Machine and Plant Components
No. 2058-9601-100
Edition 1110
GEA Mechanical Equipment / GEA Westfalia Separator Group

2 2058-9601-100 / 1110
ORIGINAL INSTRUCTIONS
The authors are always grateful for comments and suggestions for improving
the documentation. They can be addressed to:

Werner-Habig-Str. 1, 59302 Oelde
Tel. +49 2522 77-0, Fax +49 2522 77-2488
ws.info@geagroup.com, www.westfalia-separator.com
®
Westfalia Separator
2058-9601-100 / 1110 3
1 About this document 5
1.1 Scope of application ................................................................................ 6

1.2 Qualification of the personnel .................................................................. 6
1.2.1 Operating personnel ................................................................................ 6
1.2.2 Service and repair personnel ................................................................... 6
1.3 Structure of the documentation................................................................ 7
1.4 Symbols used .......................................................................................... 7
1.5 Warnings .................................................................................................. 8
2 Safety precautions 9
2.1 Intended use .......................................................................................... 10

2.2 Non-compliance with the intended use .................................................. 10
2.3 Residual risk .......................................................................................... 10
2.4 Safety markings ..................................................................................... 11
2.5 Safety instructions for the personnel ..................................................... 12
2.6 Adjustments / commissioning ................................................................ 12
2.7 Maintenance and servicing .................................................................... 12
2.8 Special types of hazard ......................................................................... 12
2.8.1 Electricity................................................................................................ 12
2.9 Oils, greases and other chemical substances ....................................... 13
3 Product overview 15
3.1 Description and operating principles ..................................................... 16

3.2 Operating conditions .............................................................................. 16
3.3 Transport................................................................................................ 16
3.4 Storage .................................................................................................. 16
4 Installation 17
4.1 Measures to be taken prior to installation .............................................. 18

4.2 Mounting ................................................................................................ 18
4.2.1 Fitting with threaded connection ............................................................ 18
4.2.2 Fitting with flange connection ................................................................ 18
4.3 Electrical connection .............................................................................. 19
4.4 Pneumatic connection ........................................................................... 19
4.5 Explosion-hazarded zone ...................................................................... 19
5 Maintenance and servicing 21
5.1 Cleaning and care .................................................................................. 22

5.2 Maintenance .......................................................................................... 22
5.3 Repair .................................................................................................... 22
6 Disposal 23
®
Westfalia Separator
4 2058-9601-100 / 1110
7 Spare parts 23
®
Westfalia Separator
2058-9601-100 / 1110 5
1 About this document
1.1 Scope of application ................................................................................ 6

1.2 Qualification of the personnel .................................................................. 6
1.2.1 Operating personnel ................................................................................ 6
1.2.2 Service and repair personnel ................................................................... 6
1.3 Structure of the documentation................................................................ 7
1.4 Symbols used .......................................................................................... 7
1.5 Warnings .................................................................................................. 8
®
Westfalia Separator
6 2058-9601-100 / 1110
1.1 Scope of application

These Safety Precautions and User Instructions provide important support for
– avoiding risks,
– reducing repair cost and down times, and
– extending the life cycle of components
The term “component” will be used in singular although this document is appli-
cable to all components incorporated in the separators/plants.
To ensure perfect operating safety of the component, these safety precautions
and user instructions have to be thoroughly read and understood prior to:
– installation
– transport, storage
– maintenance work (cleaning and care, maintenance, servicing, repair) and
– disposal
For questions that cannot be solved with the aid of this documentation, please
check back with GEA Westfalia Separator Group.
1.2 Qualification of the personnel

Using these safety and user instructions and direct handling of the component
require specialist qualification of the staff. For identifying the qualification level
GEA Westfalia Separator Group uses the following standard terms:
1.2.1 Operating personnel

• Qualified staff have the necessary technical know-how and extensive ex-
perience enabling them to avoid the risks that can arise when handling elec-
trical or mechanical components. English language skills are prerequisite.
• Trained staff are instructed or supervised by qualified staff to enable them to
avoid the risks that can arise when handling electrical or mechanical compo-
nents.
When installing, operating and testing the equipment, the staff has to adhere to
the safety rules applicable in the respective industry.
1.2.2 Service and repair personnel

Service and repair work require specialist knowledge and skills. Such work may
be carried out only by competent persons in terms of specialist knowledge and
skills. Documents in English are provided for this circle of persons. It is essential
that this circle of persons has an adequate command of English.
®
Westfalia Separator
2058-9601-100 / 1110 7
1.3 Structure of the documentation
Danger through non-observance of the documentation

• Refer to all the documents listed!
– Instruction manuals for separators and/or start-up and shut-down instruc-
WARNING! tions for plants
– Safety and user instructions on machine and plant documentation
– Component manual
• All safety precautions and warning instructions given in the documents have
to be adhered to!
• Access to the documentation on site must be ensured at all times.
The standard documentation for components comprises:
1. Instruction manuals for separators and/or start-up and shut-down instruc-

tions for plants
2. Safety and user instructions on machine and plant documentation (this
document).
3. Reference to component manual and / or technical datasheet of the com-
ponent.
1.4 Symbols used
This symbol gives information for better understanding the compo-

nent and its functions.
• A bullet point used when describing work and/or operation steps.

Be sure to proceed in correct order: from top to bottom.
– The dash (horizontal bar) is used for listing.
®
Westfalia Separator
8 2058-9601-100 / 1110
1.5 Warnings
Hazards are marked as warnings with a signal word reflecting the gravity and
probability and allocated safety colours according to ANSI Z535;
Warning Meaning
Stands for an impending threat of a hazard which will result in

severe physical injury or even death.
ALARM
Stands for a potentially hazardous situation which could result

in severe physical injury or death.
WARNING!
Stands for a potentially hazardous situation which could result

in minor physical injury. This signal word can also be used for
warnings against damage to assets.
CAUTION!
®
Westfalia Separator
2058-9601-100 / 1110 9
2.1 Intended use .......................................................................................... 10

2.3 Residual risk .......................................................................................... 10
2.4 Safety markings ..................................................................................... 11
2.5 Safety instructions for the personnel ..................................................... 12
2.6 Adjustments / commissioning ................................................................ 12
2.7 Maintenance and servicing .................................................................... 12
2.8 Special types of hazard ......................................................................... 12
2.8.1 Electricity................................................................................................ 12
2.9 Oils, greases and other chemical substances ....................................... 13
®
Westfalia Separator
10 2058-9601-100 / 1110
The machine or plant component is built according to state-of-the-art and to

prevailing safety rules and regulations. However, when using the component,
risks may arise for the user or third party or the component or other assets
might get damaged if it is
– operated by untrained or uninstructed staff,
– incorrectly used,
– inadequately maintained or serviced.
2.1 Intended use

The component is incorporated in machines and plants.
Precise details on the function of the component are found in the component
manufacturer’s manual.
The characteristics of the medium specified in the data sheet and the pressure
and temperature limit values for the medium mentioned in the specification must
be adhered to at all times.
The specific values stated in the documents furnished with the component have
to be observed and adhered to.
Any use in an explosion-hazarded area is not allowed. The only exception: this
is confirmed in the order or is mentioned in the Instruction Manual or in the
manufacturer’s data sheet.
2.2 Non-compliance with the intended use

Any use that deviates from or exceeds the intended use is considered to be
non-compliant. Solely the user of the machine/plant will be responsible for dam-
age resulting from incorrect usage. This also applies to modifications performed
on one’s own.
Non-intended use is the use of
– materials with excessively high temperature
– materials under excessively high pressure
– material containing smouldering, burning, or sticking particles
– highly explosive and pasty materials
– materials chemically reacting with the material of the component
The user is solely responsible for the operation and/or rating of the component.
Incorrect usage of components

Death or severe bodily injury to persons or damage to assets through disre-
garding mechanical, chemical and electrical risks.
WARNING!
• The specific values stated in the documents furnished with the component
have to be observed and adhered to.
2.3 Residual risk

An element of risk will remain when using the components, even when strictly
adhering to all safety rules and regulations.
Any person working with the component has to be aware of these remaining
risks and must follow all the instructions avoiding accidents or damage.
®
Westfalia Separator
2058-9601-100 / 1110 11
Hazardous voltage - danger to life

Risk of death or serious injury through electric shock!
DANGER • Work on electric apparatus and/or on live component equipment must be
performed by qualified staff only.
• Disconnect the power supply to electric equipment if required.
• Secure against unexpected restarting.
• Apply a warning sign prohibiting switching back on.
Danger when not using personal protective equipment

Risk of lethal injury when not using personal protective equipment (PPE)!
• Operating/maintenance staff must be obliged to wear PPE.
DANGER
• Wear safety boots, safety goggles, ear protection, etc., depending on tasks
and conditions.
• When surface temperatures of > 50 °C or < 0 °C (> 122 °F or < 32 °F) pre-
vail, wear temperature-resistant protective gloves when working on compo-
nents.
Danger through lack of attention when working in the area of the compo-
nent
Crushing, cutting and abrasion injuries.
WARNING! • Be sure to work and move carefully in the area around the component.
Risk of eye and/or skin injuries when medium discharges under high
pressure
Abrasive or corrosive substances destroy the component!
WARNING!
• Wear protective goggles or face-mask with eye protection against spouting
medium.
2.4 Safety markings

The following markings (adhesive and metal plates) are fastened to the compo-
nent or its accessories:
Warning of dangerous voltage!
The sign is fastened on the electric terminal box.

The terminal box may only be opened by a qualified electrician.
Nameplate The nameplate contains specific component data.
All safety markings must always be in perfect condition.

• Note the safety marking.
®
Westfalia Separator
12 2058-9601-100 / 1110
2.5 Safety instructions for the personnel

The component must be operated only in perfect condition, for the intended use,
taking into account security rules and being aware of risks, duly adhering to the
documentation.
Any fault – especially those potentially impairing safety - must be remedied im-
mediately!
Clearly define and adhere to responsibilities for operation and maintenance.
This is the only way to avoid errors – especially in dangerous situations.
Do not use the component until all protection and safety devices are installed
and serviceable! Do NOT remove them during operation.
In case of malfunction or safety-relevant change in operational behaviour, shut
down and secure the separator or the plant. Have faults remedied by qualified
staff immediately.
Leaking dangerous material must be discharged so as to avoid danger to the
operator and to the environment.
Do NOT touch damaged, cracked and, especially, live components.
2.6 Adjustments / commissioning

The medium throughput might change or be interrupted while the component is
being commissioned. Prior to commissioning, make sure that there will be no
risk for people or the environment while performing adjustments.
Each adjustment must be followed by a functional check.
Take appropriate measures to prevent crushing injuries by moving adjustment
devices.
2.7 Maintenance and servicing

When carrying out maintenance work, strictly adhere to all rules and regulations
applicable for handling the component or the medium (e.g. protective clothing,
no smoking).
Adhere to the check-up or inspection intervals specified in applicable laws
and/or in the documentation.
Check wires and hoses for damage and replace if necessary, especially on
moving components.
2.8 Special types of hazard
2.8.1 Electricity
Never carry out work on live parts!
Do not change safety-related design parameters! Especially, do NOT restrict
leakage paths, air gaps, and clearances with insulating coatings.
Check wires for damage at regular intervals and replace if necessary.
®
Westfalia Separator
2058-9601-100 / 1110 13
2.9 Oils, greases and other chemical substances

When handling oils, greases, and chemicals, adhere to the applicable rules and
regulations and manufacturers’ data sheets for these materials concerning stor-
age, handling, usage, and disposal!
After eye or skin contact, rinse the affected area immediately with water.
®
Westfalia Separator
14 2058-9601-100 / 1110
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note
®
Westfalia Separator
2058-9601-100 / 1110 15
3 Product overview
3.1 Description and operating principles ..................................................... 16

3.2 Operating conditions .............................................................................. 16
3.3 Transport................................................................................................ 16
3.4 Storage .................................................................................................. 16
®
Westfalia Separator
16 2058-9601-100 / 1110
3.1 Description and operating principles

The detailed description and functional principle of the respective component
are given in the corresponding component manual.
3.2 Operating conditions

Housing and gasket materials are selected in accordance with operating condi-
tions. Operating conditions essentially determine the service live of the compo-
nent.
• Technical characteristics and the essential permissible limit values, especially
for pressure and temperature of the medium, are given in the manufacturer’s
manual.
• Care must be taken that the component is only used where the rating criteria
comply with the values stated on the nameplate. Correct transport and appro-
priate storage are prerequisite.
• Faults arising from moving elements must be prevented by taking appropriate
measures.
3.3 Transport
Be sure to comply with the following:
Danger through contact with substances hazardous to health

During operation the component might have come into contact with substances
that are hazardous to health.
WARNING!
• De-contaminate the component prior to packing and/or transport.
• Use lifting devices to transport heavy components that cannot be moved by

hand.
• Screw eye bolts or lugs into the component and suspend them properly to the
lifting device, and then transport.
• When using lifting straps, place them around the component, provide sharp-
edge protection if required, and watch for proper weight distribution.
• During transport, protect the component against external force (impacts, vi-
bration, etc.).
• Protect the sealing surfaces of connections against damage.
• Do not damage the corrosion-preventive coating.
3.4 Storage
• Protect the component against external impacts and contamination.
– Keep the storage room as dry and dust-free as possible.
– Avoid water condensation.
– Protect open connection ports from dirt.
®
Westfalia Separator
2058-9601-100 / 1110 17
4 Installation
4.1 Measures to be taken prior to installation .............................................. 18

4.2 Mounting ................................................................................................ 18
4.2.1 Fitting with threaded connection ............................................................ 18
4.2.2 Fitting with flange connection ................................................................ 18
4.3 Electrical connection .............................................................................. 19
4.4 Pneumatic connection ........................................................................... 19
4.5 Explosion-hazarded zone ...................................................................... 19
®
Westfalia Separator
18 2058-9601-100 / 1110
• Refer to the component manual for specific information on the component.

• Before installation, read and follow the instructions in the chapter “Safety pre-
cautions”.
4.1 Measures to be taken prior to installation
Packaging damaged during transport and/or storage

Component might not comply with safety rules.
• Check for possible damage prior to installation.
CAUTION!
• Do not install any defective component.
Ta ke th e fo llo win g m e a s u re s p rio r to in s ta lla tio n :

• Check that the line system and the component are perfectly clean.
• Remove protection caps from the connectors directly before installation only.
• Do NOT damage sealing surfaces and threads respectively.
4.2 Mounting
• Remove all packaging material immediately before installation only.
• No dirt particles must seep into the component!
• Bear in mind the flow direction indicated on the component if required.
Afte r in s ta lla tio n

• Check for possible leakage and for proper function.
• Create the specified operating status.
4.2.1 Fitting with threaded connection

• Use appropriate sealing aid.
• Arrange the piping layout so that flux across the component will be avoided.
4.2.2 Fitting with flange connection

• Use the specified screws. Use all the flange bores provided.
• Insert appropriate seals and center them properly between the flanges.
• Tighten the screws evenly and crosswise to prevent warping. Under no cir-
cumstances should the pipeline be pulled against the component.
• Watch for proper location of seals.
• Tighten screws to the specified torques.
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4.3 Electrical connection

For a component with electric equipment:
Hazardous voltage - danger to life

Risk of death or serious injury through electric shock!
DANGER
• Work on electric apparatus and/or on live component equipment must be
performed by qualified staff only.
• Disconnect the power supply to electric equipment.
• Prevent unexpected restarting.
• Apply a warning sign prohibiting switching back on.
• Earth the component according to local rules.
• Take adequate preventive measures according to the provisions of the local
electric power company.
4.4 Pneumatic connection

Actuate only with treated compressed air. If necessary, install a compressed air
control unit upstream-
4.5 Explosion-hazarded zone

Any use in an explosion-hazarded area is not allowed. The only exception: this
is confirmed in the order or is mentioned in the Manual or in the manufacturer’s
data sheet.
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Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note
®
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2058-9601-100 / 1110 21
5 Maintenance and servicing
5.1 Cleaning and care .................................................................................. 22

5.2 Maintenance .......................................................................................... 22
5.3 Repair .................................................................................................... 22
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This chapter comprises: cleaning and servicing, maintenance and repair.

• Before carrying out maintenance and repair, read and follow the instructions
in the chapter “Safety precautions”.
5.1 Cleaning and care
Damage to the component, caused by a layer of dirt

Clogging of functional openings. Impairment of heat dissipation!
• Arrange for efficient covering of the component when carrying out dirty work
CAUTION!
near the separator or the plant (e.g. laying concrete, brickwork, painting, sand-
blasting).
• Clean the component regularly.
Malfunction due to damage to the component

Risk of material damage through inappropriate cleaning!
• When cleaning with aqueous detergents, note the type of protection of electric
CAUTION! components. Do not apply them when in doubt!
• Do not use aggressive cleaning agents. Otherwise metal or plastic surfaces as
well as hose connections might be attacked.
• Never clean sensitive components with hard brushes applying excessive force.
• Use lint-free cleaning rags only.
5.2 Maintenance
• The maintenance intervals have to be re-determined (shortened) by the op-
erator according to prevailing operating conditions.
• Check or maintain the component for safety reasons. When doing so, observe
the following minimum requirements:
– Check visible condition of the component and its accessories at regular in-
tervals.
– Actuate the component parts on a regular basis to ensure that proper func-
tioning of all moving parts will not be impaired by long-term standstill.
5.3 Repair
Material damage due to mechanical overload on component parts

Impacts by kicks, mechanical stress originating from connected pipelines, ex-
cessive ambient temperatures will destroy the component!
WARNING!
• Install parts without force. Avoid tension and strain.
• Avoid excessive load, e.g. impacts by kicks (wrongfully climbing on the com-
ponent).
• Avoid welding and thermal treatment.
• Avoid working on the components with tools (e.g. drilling).
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6 Disposal
• Comply with the prevailing statutory regulations to ensure proper, environ-

mentally sound disposal.
Danger through contact with substances hazardous to health

During operation the component might have come into contact with substances
that are hazardous to health.
WARNING!
• Decontaminate prior to disposal.
7 Spare parts
Spare, wear parts and operating materials can cause damage

to persons and assets if they do not meet the requirements.
Genuine spare parts and operating materials from GEA West-
falia Separator Group satisfy all requirements for the operating
safety of the machine or installation.
• Use only genuine spare parts.
• Use only original operating materials.
• Use the spare parts catalogue supplied.
®
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24 2058-9601-100 / 1110
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note
®
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2058-9601-100 / 1110 25
®
Westfalia Separator
Werner-Habig-Str. 1, 59302 Oelde (Germany)
Phone +49 2522 77-0, Fax +49 2522 77-2488
Installation Instructions
For Separators
No. 2058-9601-020
Edition 0211
GEA Mechanical Equipment / GEA Westfalia Separator Group

2 2058-9601-020 / 0211
ORIGINAL INSTRUCTION MANUAL

the documentation. They can be addressed to:

Phone +49 2522 77-0, Fax +49 2522 77-2488
®
Westfalia Separator
2058-9601-020 / 0211 3
Preface
These installation guidelines
• are part of the overall documentation compiled for the separator.
• describe the procedures for constructing, manufacturing and design-
ing separators.
• contain fundamental instructions for installing separator installations.
• contain general guidelines for separator installations.
These guidelines specify the minimum specifications for designing and

constructing frames, tanks, piping and the electrical installation.
Putting together and installing the installation components must be

carried out in accordance with the order-specific documents:
• Installation diagram and equipment list
• Dimensioned drawing (notes on required space for operating and
servicing, minimum clearance from walls/pillars or other machines)
We reserve the right to carry out technical modifications on the

separator!
Attention must be paid to the operating, maintenance and mounting

instruction manuals of all units and fittings.
For your safety

symbol -
otherwise danger to life!

This avoids damage to the separator and other equipment.
mation which help to better understand the separator or plant compo-
nents and the processes.
• Use only genuine spare parts from GEA Westfalia Separator. The origi-
nal spare parts are listed in the spare parts catalog.
– safety risks,
– reduced durability of these parts,
– reduced availability of the separator and
If a safety risk occurs when using non-original spare parts, this may have legal
consequences for the responsible persons. In such cases, GEA Westfalia
Separator accepts no liability or warranty claims.
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Westfalia Separator
4 2058-9601-020 / 0211
1 General 7
1.1 Safety precautions ................................................................................... 8

1.2 Material .................................................................................................... 8
1.3 Installation ................................................................................................ 8
1.4 Storage .................................................................................................. 10
1.4.1 Installation of controls ............................................................................ 10
1.5 Transport................................................................................................ 12
1.5.1 Transporting the separator .................................................................... 14
1.6 Preservation measures on site .............................................................. 18
2 Separator 19
2.1 Space requirement for separators ......................................................... 20

2.1.1 Separators with belt drive ...................................................................... 20
2.2 Bowl weights .......................................................................................... 22
2.3 Required hoist specifications for separators.......................................... 23
2.4 Ventilating the separator room .............................................................. 23
2.5 Foundations ........................................................................................... 25
2.6 Securing the separators ......................................................................... 27
2.6.1 Separators OSD 6, 18, 35, 60, OSE 5, 10, 20, 40, 80 and
OTC 5, 10, 20 ........................................................................................ 28
2.7 Welding procedure for fastening the foundation frame ......................... 29
2.7.1 Installing the separator .......................................................................... 30
2.8 Vibrations ............................................................................................... 31
2.9 Pipelines on the separator ..................................................................... 32
2.9.1 Product line ............................................................................................ 32
2.9.2 Operating, filling and displacement water lines ..................................... 32
3 Operating, filling and displacement water 33
3.1 Water quality .......................................................................................... 34

3.2 Supply pressure and temperature ......................................................... 34
3.3 Water connection for operating, filling and displacement water ............ 35
3.4 Dimensions and number of consumers ................................................. 35
3.5 Water quantity ........................................................................................ 36
4 Compressed air 37
4.1 Compressed air quality .......................................................................... 38

4.2 Supply pressure ..................................................................................... 38
4.3 Compressed air consumption of the separators OSD, OSE and OTC.. 38
5 Product lines 39
5.1 General .................................................................................................. 40

5.2 Pipe cross-sections ................................................................................ 40
5.3 Functional description ............................................................................ 40
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5.4 Information on pressure monitoring ....................................................... 40

5.5 Piping ..................................................................................................... 42
5.6 Maximum suction head .......................................................................... 43
5.6.1 Pressure line .......................................................................................... 43
5.6.2 Pre-filter ................................................................................................. 44
5.7 Feed pump ............................................................................................. 44
5.8 Oil pre-heater ......................................................................................... 44
5.9 Installation examples ............................................................................. 45
5.9.1 Steam-heated plate heat exchanger with (PI controlled) control valve . 45
5.9.2 Steam-heated tubular heat exchanger with (PI controlled)
control valve ........................................................................................... 46
5.9.3 Thermal oil-heated plate heat exchanger with (PI controlled) control
valve....................................................................................................... 47
5.9.4 Thermal-oil-heated tubular heat exchanger with (PI controlled)
control valve ........................................................................................... 48
5.10 Securing plate heat exchangers ............................................................ 49
5.11 Safety valve ........................................................................................... 50
6 Solids tank 51
6.1 Recommended criteria for solids tank ................................................... 52

6.1.1 Tank vent ............................................................................................... 53
6.1.2 Set-up of the solids tank venting ........................................................... 54
6.2 Solids discharge lines ............................................................................ 55
6.2.1 Solids discharge lines with shut-off flap................................................. 56
6.2.2 Standard installation of shut-off flaps .................................................... 56
6.2.3 Installation recommendation for shut-off flaps ....................................... 57
6.3 Operating and dirty water discharge lines ............................................. 58
6.3.1 Separators of OSD and OSE ................................................................. 58
7 Electrical installation 61
7.1 Control cabinet ....................................................................................... 62

7.1.1 Electrical connection .............................................................................. 64
7.1.2 External voltages ................................................................................... 64
7.1.3 Shipboard operation .............................................................................. 65
7.1.4 Onshore operation ................................................................................. 65
7.2 Electro-magnetically compatible installation .......................................... 66
7.3 Valves .................................................................................................... 67
7.3.1 Solenoid valve block .............................................................................. 67
7.3.2 Terminal box .......................................................................................... 68
7.3.3 Separator with sensor bloc .................................................................... 69
7.4 Dual-purpose thermometer .................................................................... 70
7.5 Electrical installation of transmitters and electric motors ....................... 71
7.6 Electrical execution ................................................................................ 71
7.6.1 Earthing the separator ........................................................................... 72
7.6.2 Voltage equalisation of the separator .................................................... 72
7.6.3 Voltage equalization of the electric heater ............................................. 73
7.6.4 Voltage equalization of the foundation frame ........................................ 73
7.6.5 Voltage equalisation of the control cabinet ............................................ 74
7.7 Electric motors procured by the customer ............................................. 75
7.8 Installation and operation of control units .............................................. 76
®
Westfalia Separator
6 2058-9601-020 / 0211
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note
®
Westfalia Separator
2058-9601-020 / 0211 7
1 General
1.1 Safety precautions ................................................................................... 8

1.2 Material .................................................................................................... 8
1.3 Installation ................................................................................................ 8
1.4 Storage .................................................................................................. 10
1.4.1 Installation of controls ............................................................................ 10
1.5 Transport................................................................................................ 12
1.6 Preservation measures on site .............................................................. 18
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1.1 Safety precautions

• Pay special attention to the safety precautions contained in the
overall documentation compiled for the separator!
1.2 Material
• The specified material must conform to the standards set out in these installa-
tion guidelines as a minimum requirement.
• All materials used must be new and from the same series.
1.3 Installation
Fig. 1 Installation example
1 Separator: 7 Solids tank venting

2 Separator foundation 8 Crane
3 Control unit 9 Cleaning table
4 Control cabinet 10 Aeration
5 Preheater 11 Venting
6 Solids tank
• The applicable regulations and standards of classification societies or other

authorised bodies must be observed.
• All lubricating points and the gear / drive housing of the separator must be
easily accessible without having to remove pipes or gratings.
• All operating elements must be within comfortable reach of the operator and
at a suitable height.
• Operating elements must not be mounted higher than 1800 mm above the
working platform.
• All units must be arranged so that they do not cramp the working area and so
that they can be safely serviced and operated.
®
Westfalia Separator
2058-9601-020 / 0211 9
• All fixed piping and fittings must be safely supported to reduce vibrations and
movement to a minimum.
• Contact points or supports must be fitted so that the pipes are able to move
with changing temperatures without creating tension in the pipes.
• Pipes and pipe connections must be accessible for maintenance.
• Pipes must not be used for supporting distributors or appliances.
• These regulations and standards do not apply to small purpose-built parts
whose durability, accessibility and operation are not influenced. They must be
fitted in accordance with the manufacturer's recommendations.
• No galvanized parts may be fitted in product-carrying lines (e.g. heavy oil,
diesel oil, steam lines and thermal oil lines). This does not apply if type-tested
pipe joints are fitted in pipe trace heating systems.
• Y-strainers should preferably be fitted horizontally with the strainer insert
pointing downwards or to the side (turned through 90°).
If this is not possible for space reasons, the dirt pan can be fitted vertically
with a throughflow from top to bottom. In this case, ensure that the strainer
can be dismantled.
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10 2058-9601-020 / 0211
1.4 Storage
• Parts may be stored only in original GEA Westfalia Separator transport pack-
aging.
• A storage time of more than 12 months is only possible after consulting the
manufacturer.
• The storage site should be a closed, dry room.
• The storage temperature must not be below 5°C (41 F) and must not exceed
50 °C (122 °F).
IMPORTANT:
• Outdoor exposure is not admissible!
Pay attention to the following points on storage and transport packaging.
• Handle fragile goods with care!
• Protect the goods against moisture and humidity.
• Protect the goods against heat!
• Pay attention when erecting the goods.
1.4.1 Installation of controls
IMPORTANT:
• Select the installation site so that

– the control unit is not exposed to dust and aggressive atmosphere.
– the control unit is not installed in an excessively humid environment or
damp area.
– the sun cannot shine on the control panel or displays making operation and
observation more difficult.
– heating up of the control unit is avoided.
• Where appropriate, check screw-type and plug-type connectors for secure
contact.
®
Westfalia Separator
2058-9601-020 / 0211 11
• Connect thermostatically controlled cabinet heating to external voltage and

switch it on.
• The control cabinet heating must switch on before the temperature drops be-
low the dew point.
• Bedewing can occur during the night which is not good for electronic appara-
tus.
• Check that the line voltage and frequency conform to the connection data of
the control unit (see nameplate).
• Pay attention to admissible installation and operating data:
Voltage fluctuations +/- 10 % of the line voltage

Frequency fluctuations +/- 2 % of the line voltage
Ambient temperatures + 5 to + 45 °C (41 to 113 °F)
Atmospheric humidity max. 50 % at 40 °C (104 °F)
max. 90 % at 20 °C (68 °F)
Installation height above sea level up to 1000 m
Transport temperatures – 25 to + 55 °C (–13 to 131 °F)
IMPORTANT:
Improper installation and operation discharges the supplier from the warranty
obligation.
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12 2058-9601-020 / 0211
1.5 Transport
The adjacent packing illustrates a

seaworthy packaging from GEA West-
falia Separator.
Fig. 2
• After removing the side boards and

filling material, the bottom board can
be used as a special pallet for fork
lift trucks.
Fig. 3
• If no forklift trucks are available,

transport the case with the aid of a
crane (see diagram).
• Attach the ropes to the points on the
packing case as marked on the
packing case.
Fig. 4
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2058-9601-020 / 0211 13
• Attach ropes round the case and

hang them into the load hook of the
crane.
• CAUTION!
Wind one piece of rope twice
round the hook to prevent the
ropes from slipping.
Fig. 5
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1.5.1 Transporting the separator
• IMPORTANT:
To avoid damage, the bowl must be
removed from the separator before
transport.
• The separator is normally delivered
without installed bowl.
Exception:
• The OTC 2, OTC 3, OSD 2 and
OSE 5 separators are delivered and
transported with installed bowl.
Fig. 6
CAUTION!
Prevent accidents by using suitably rated hoists for transport and installa-
tion.
• When transporting rope, make sure

that one piece of rope is wound
twice round the hook to prevent the
• The rope must be properly attached
to the separator.
• Ensure that no pulling or pushing
forces act on machine parts when
using ropes.
Fig. 7
The following examples show how the transport ropes must be attached on the
different frame designs (see Fig. 8 – Fig. 13).
®
Westfalia Separator
2058-9601-020 / 0211 15
For OSD 6 or 18 and OSE 5, 10 and 20 – separator with belt drive
• Screw double nipple 1 into the hole

in the frame.
Fig. 8
• Attach the transport ropes

– to the machine as illustrated and
– hang them into the load hook of
the hoist as illustrated.
• Make sure that the ropes do not
damage any machine components.
• Do not use the eye bolt of the

motor to suspend the separator.
• Make sure the machine touches
down gently.
Fig. 9
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16 2058-9601-020 / 0211
For OSD 35 and OSE 40 – separator with belt drive
• Screw two eye bolts 1 into the upper

section of the frame.
in the frame.
Fig. 10

– around the double nipple.
– Thread through the eye bolts and

down gently.
Fig. 11
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2058-9601-020 / 0211 17
For OSD 60, OSE 80 and 120 – separator with belt drive
• Check that
– two eye bolts 1 are screwed into
the upper section of the frame.
– Screw two eye bolts 2 with wash-
ers 3 into the intermediate flange /
frame holes.
Fig. 12

– Thread through the four eye bolts
and

down gently.
Fig. 13
®
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18 2058-9601-020 / 0211
1.6 Preservation measures on site
After installation until commissioning

• All parts such as tools, spare parts and bowl must be stored in the original
packaging in a suitable place until commissioning.
• The parts must be stored at 5 to 50 °C (41 - 122 °F) in dry, weatherproof
rooms to prevent the packaging from getting damaged.
• The spindle and gear/drive chamber are lubricated at the factory which pro-
tects them for a period of 12 months.
• In the case of a storage and standstill period of longer than 12 months, the
time-dependent maintenance intervals specified in the instruction manual
must be adhered to before putting the machine back into operation.
• After this time (12 months) has expired, it must be checked at 12 monthly in-
tervals that all bearings and the spindle have sufficient lubrication.
• Oil to be used:
– Shell oil S.7294 (SAE 30/SAE 50) for bearings and spindle,
– roller bearing grease for the spindle cap.
®
Westfalia Separator
2058-9601-020 / 0211 19
2 Separator
2.1 Space requirement for separators ......................................................... 20

2.1.1 Separators with belt drive ...................................................................... 20
2.2 Bowl weights .......................................................................................... 22
2.3 Required hoist specifications for separators.......................................... 23
2.4 Ventilating the separator room .............................................................. 23
2.5 Foundations ........................................................................................... 25
2.6 Securing the separators ......................................................................... 27
2.6.1 Separators OSD 6, 18, 35, 60, OSE 5, 10, 20, 40, 80 and
OTC 5, 10, 20 ........................................................................................ 28
2.7 Welding procedure for fastening the foundation frame ......................... 29
2.8 Vibrations ............................................................................................... 31
2.9 Pipelines on the separator ..................................................................... 32
2.9.1 Product line ............................................................................................ 32
2.9.2 Operating, filling and displacement water lines ..................................... 32
®
Westfalia Separator
20 2058-9601-020 / 0211
2.1 Space requirement for separators

• No piping may be laid in the operating area apart from the feed and discharge
lines for the separator.
2.1.1 Separators with belt drive
• The hatched area represents the operating area.

• See the following table to determine the operating area.
• Before installing the separator, pay special attention to the removal dimension
X for the electric motors!
Front view of separator
Fig. 14
Side view of separator
Fig. 15
Top view of separator
Fig. 16
®
Westfalia Separator
2058-9601-020 / 0211 21
Table for determining the operating area for separators with belt drive
Separator Dimensions in mm
model A B D E F G X Y
OTC 2 800 300 800 120 - 280 100 150
OTC 3 800 300 800 120 - 280 100 150
OTC 5 1400 600 1200 400 1250 375 540 150
OTC 10 1400 600 1400 550 1450 540 540 150
OTC 20 1400 600 1400 550 1550 630 630 150
OSD 2 800 300 800 200 - 280 100 150
OSD 6 1400 600 1400 550 1450 540 180 150
OSD 18 1400 600 1400 550 1550 630 180 150
OSD 35 1800 700 1800 650 1950 850 230 200
OSD 60 2000 800 2000 700 2500 1000 300 200
OSE 5 1400 600 1200 400 1250 375 540 150
OSE 10 1400 600 1400 550 1500 540 180 150
OSE 20 1400 600 1400 550 1650 630 180 150
OSE 40 1800 700 1800 650 2080 850 230 200
OSE 80 2000 800 2000 700 2250 1000 300 200
®
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22 2058-9601-020 / 0211
2.2 Bowl weights
Fig. 17
Table with data for rating the lifting device

Bowl weight
Separator model b h
[kg]
OSD 6 255 270 42
OSD 18 300 320 72
OSD 35 425 420 190
OSD 60 536 530 360
OTC 5 220 225 25
OTC 10 260 265 40
OTC 20 315 310 52
Bowl weight
Separator model b h
[kg]
OSE 5 220 225 30
OSE 10 260 265 45
OSE 20 315 310 65
OSE 40 440 450 205
OSE 80 560 570 400
®
Westfalia Separator
2058-9601-020 / 0211 23
2.3 Required hoist specifications for separators
Flat belt separators

• The hoist must be travel-type or swivel-type.
• The hoist must be arranged so as to enable the following:
– Vertical fitting and removal of the bowl (see section 2.1.1, table - dimension
F).
– Horizontal removal and fitting of the drive motor (see section 2.1.1, table -
dimension X).
2.4 Ventilating the separator room

• Pay attention to the correct arrangement of the air feed and discharge lines so
that
– the separator room is efficiently ventilated,
– the admissible room temperature – normally max. 45 °C (113 °F) – is not
exceeded.
The rating of the electrical apparatus is critical in this respect.
IMPORTANT:
If the admissible temperatures are exceeded, additional measures must be
taken. Maintenance intervals and maintenance measures may have to be ad-
justed accordingly.
Installation example of a ventilation

system
1 Aeration
2 Venting
Fig. 18
Approximate values for air exchange
-1
For small closed separator rooms 30 - 50 h
-1
For large separator rooms 15 - 20 h
-1
For niches in engine rooms 50 - 70 h
®
Westfalia Separator
24 2058-9601-020 / 0211
Table for air volumes pressed out of the housing
Separator Air volume

model [m³/h]
OTC 2 10
OTC 3 10
OTC 5 10
OTC 10 10
OTC 20 10
OSD 2 10
OSD 6 10
OSD 18 30
OSD 35 100
OSD 60 150
OSE 5 10
OSE 10 10
OSE 20 30
OSE 40 100
OSE 80 150
®
Westfalia Separator
2058-9601-020 / 0211 25
2.5 Foundations
In order to avoid the influence of external vibrations,

• Foundations and foundation frames for separators must not be rigidly con-
nected to other foundations.
IMPORTANT:
• If the foundation does not have adequate rigidity and flexural strength, this
may result in loss of warranty.
Installation example for a founda-

tion frame
1 Foundation
Fig. 19
• The foundation frames must be de-

signed so that dimensions a and b in
the table below are adhered to.
• When using other sections, the sec-
tion modulus of the U-sections must
not be lower than the value specified
in DIN 1026.
• The foundation must be rigid with a
maximum admissible deflection of
1:250.
• The separator feet must be fastened
on the neutral axis of the frame.
Fig. 20
®
Westfalia Separator
26 2058-9601-020 / 0211
Table for dimensioning foundation frames
Separator Dimensions in mm
model a b
OTC 2 80 60
OTC 3 80 60
OTC 5 80 60
OTC 10 80 60
OTC 20 80 60
OSD 2 80 60
OSD 6 140 60
OSD 18 140 60
OSD 35 180 70
OSD 60 180 70
OSE 5 140 60
OSE 10 140 60
OSE 20 140 60
OSE 40 180 70
OSE 80 180 70
®
Westfalia Separator
2058-9601-020 / 0211 27
2.6 Securing the separators

The following sections show how to secure the different separators:
Separators OTC 2, OTC 3, OSD 2
Assembly of separators with the aid of

rubber-metal cushions on a steel foun-
dation frame.
Fig. 21
• Screw rubber-metal cushions 4 into

foundation 5.
• Screw studs 2 into rubber-metal
cushions 4.
• Place plate 3 over the studs.
• Place the separator on plate 3 and
• bolt tight with hexagon nuts 1.
Fig. 22
ATTENTION!
The tightening torque for the stud screw 2 (M10) must be 30 Nm.
®
Westfalia Separator
28 2058-9601-020 / 0211
2.6.1 Separators OSD 6, 18, 35, 60, OSE 5, 10, 20, 40, 80 and OTC 5, 10, 20
• Align separator 1 with feet 2 and

plates 3 on foundation 4.
• Tack plates 3.
• Unscrew screws 5.
• Lift separator with feet (see section
1.5.1).
• Weld plates 3 to foundation 4.
• Place the separator on plates 3 and
• Screw tight hex head screws 6.
Fig. 23
ATTENTION!
The torques for the hex head screw 6 are specified in the table below.
Separator model Hex head screw Torque
OSD 6
M 12 52 Nm
OSD 18
OSD 35
M 16 100 Nm
OSD 60
OSE 5
OSE 10 M 12 52 Nm
OSE 20
OSE 40
M 16 100 Nm
OSE 80
OTC 5
OTC 10 M 12 52 Nm
OTC 20
®
Westfalia Separator
2058-9601-020 / 0211 29
2.7 Welding procedure for fastening the foundation frame

The following sections show the welding procedure for fastening the foundation
frame:
Mounting the separator installations

on board of a ship
• The foundation frame 2 can be di-
rectly welded onto the steel structure
2 from the shipyard.
Fig. 24
Example 1
• The length of the weld seams must
be 100 mm.
• The distance between the weld
seams must be approx. 350 mm.
This means that that there are 3 weld

seams with a length of 100 mm along
a length of one metre.
Example 2
• The foundation frame can likewise
Fig. 25 be welded all the way round.
Detail view
In this view you can see an example
for welding the foundation frame to the
steel structure.
The letter X indicates a fillet weld.
Fig. 26
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Westfalia Separator
30 2058-9601-020 / 0211
2.7.1 Installing the separator
Mounting the separator installations

on board of a ship
• The frames must be fitted beneath
the separator feet.
• The dimension a for the frame dis-
tance must be observed.
• The position of the separator feet is
given in section 2.1.1.
Fig. 27
• The dimension a for the frame dis-

tance is given in the table below for
the respective separator model.
Fig. 28
Dimension “a”
Separator model
[mm]
OTC 2 452 mm
OTC 3 452 mm
OTC 5 326 mm
OTC 10 350 mm
OTC 20 425 mm
OSD 2 452 mm
OSD 6 350 mm
OSD 18 425 mm
OSD 35 555 mm
OSD 60 700 mm
OSE 5 326 mm
OSE 10 350 mm
OSE 20 425 mm
OSE 40 555 mm
OSE 80 700 mm
®
Westfalia Separator
2058-9601-020 / 0211 31
2.8 Vibrations
Fig. 29
Admissible vibra- Limit values for Vibro 1
Tolerable vibration values at the
Separator tion value at the with installed vibration
separator installation surface 
model reference point  sensor 
max. [mm/s]
[mm/s] [mm/s]
OTC 2 1,8 2,8 2,8
OTC 3 1,8 2,8 2,8
OTC 5 2,8 4,5 4,5
OTC 10 2,8 4,5 4,5
OTC 20 2,8 4,5 4,5
OSD 2 1,8 2,8 2,8
OSD 6 2,8 4,5 4,5
OSD 18 2,8 4,5 4,5
OSD 35 2,8 4,5 4,5
OSD 60 2,8 4,5 4,5
OSE 5 3,5 5,5 5,5
OSE 10 2,8 4,5 4,5
OSE 20 2,8 4,5 4,5
OSE 40 2,8 4,5 4,5
OSE 80 2,8 4,5 4,5
 Measured at separator standstill and normal ship operating conditions
 Measured with separators in operation
 The Vibro sensor is attached in this range
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Westfalia Separator
32 2058-9601-020 / 0211
2.9 Pipelines on the separator

The following sections describe the general set-up of the piping system in the
separator installation:
2.9.1 Product line

• Product lines must be laid
– in accordance with the guidelines of GEA Westfalia Separator or
– in accordance with the requirements of the classification societies.
• Use only genuine parts from GEA Westfalia Separator!
• The lines must be flushed before commissioning to protect the valves and
units.
• The following lines must have no rigid connection with the separator in order
to prevent vibrations:
– Product feed and discharge
– Water connection
– Solids discharge
– Dirty water discharge
– Frame drain
• This can be realised by means of hoses or compensators, whereby there are

special requirements for shockproof separators.
• Hose pipes must be laid so that they cannot be twisted, kinked, clamped or
rubbed.
• Use only hoses from GEA Westfalia Separator!
2.9.2 Operating, filling and displacement water lines

• Water lines must be laid so that they can be completely drained at the lowest
point with no dismantling.
• Y-strainers are fitted horizontally at the factory – with the strainer insert point-
ing downwards. See section 1.3 – Installation.
• The solenoid valves for operating, filling and displacement water to the sepa-
rator are fitted so that the hose between the separator and solenoid valves
cannot empty.
®
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3 Operating, filling and displacement water
3.1 Water quality .......................................................................................... 34

3.2 Supply pressure and temperature ......................................................... 34
3.3 Water connection for operating, filling and displacement water ............ 35
3.4 Dimensions and number of consumers ................................................. 35
3.5 Water quantity ........................................................................................ 36
®
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34 2058-9601-020 / 0211
3.1 Water quality

• The water should be as pure as possible and meet the following standards:
Hardness:
– up to 55 °C (131 °F) separating temperature < 12° dH
– above 55 °C (131 °F) separating temperature < 6° dH
Note:
– When using demineralised water or condensate, corrosion must be
reckoned with.
– The use of boiler feed water is not permissible!
– Land water is not recommended because the degrees of hardness are
normally too high.
To convert the hardness values stated, use the following equation:
1° dH = 1,79° fH = 1,25° eH = 17,9 ppm CaCO3
pH 6,5 – 8,5
Chloride ions < 100 mg/l
Suspended matter max. 10 mg/l
Particle size max. 50 µm
3.2 Supply pressure and temperature
Fig. 30
Note:
The pressure after the water pressure reducer must not drop below 0.2 Mpa
with open operating water valve.
• The supply pressure and the temperature for the operating, filling and dis-
placement water must meet the following specifications:
Temperature min. 10 °C (50 °F)

max. 85 °C (185 °F)
Supply pressure 0.3 – 1.0 MPa
®
Westfalia Separator
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3.3 Water connection for operating, filling and displacement water

• Pay special attention to section 2.9.2!
3.4 Dimensions and number of consumers

• Collective lines must be dimensioned so that the separators are always sup-
plied with an adequate water volume to assure perfect functioning.
• Lines must be laid so that manual override of the valves and filter replace-
ment are possible.
• The maximum length between pressure reducer and solenoid valve must not
exceed 5 m.
• In the case of 1 consumer, the col-

lective line must have the same
nominal diameter as the feed lines
to the separator.
• The nominal diameter R is given in
the table below.
Fig. 31
Fig. 32
In the case of 2 consumers:

• the collective line must have a nominal diameter S (see table).
• the supply lines to the separator must have a nominal diameter R (see table).
Note:
When two separators request water at different times, the water supply can be
rated as for one separator.
®
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36 2058-9601-020 / 0211
In the case of 3 consumers:

• the collective line must have a nominal diameter of DN 32.
• the supply lines to the separator must have a nominal diameter R (see table).
Table for selecting the nominal diameters “S” and “R”.

Nominal diameter (DN)
Separator model Collective line Supply line
S R
OSD 2 25 20
OSD 6 25 20
OSD 18 25 20
OSD 35 32 20
OSD 60 32 20
OSE 5 25 20
OSE 10 25 20
OSE 20 25 20
OSE 40 32 20
OSE 80 32 20
3.5 Water quantity

For exact program control, with simultaneous actuation of the valves, the follow-
ing water quantities are required:
V2 V2 V3 Total con-
Total consumption
sumption per cycle
Separator Displace- Operating per cycle without
Filling water
model ment water water * filling wa-
ter
l/s l/s l/s Approx. 1
OSD 2 0,25 0,25 0,25 2 1,5
OSD 6 0,1 0,1 0,5 3 2
OSD 18 0,1 0,1 0,8 5 3,5
OSD 35 0,1 0,1 0,8 10 6,5
OSD 60 0,1 0,1 0,8 23 13
OSE 5 0,1 0,1 0,5 1,6 1,1
OSE 10 0,1 0,1 0,5 2,3 1,5
OSE 20 0,1 0,1 0,5 3,2 2,0
OSE 40 0,1 0,1 0,8 11,6 7,6
OSE 80 0,1 0,1 0,8 25,4 15,4
* Ejection cycle = Σ (filling water + displacement water + operating water)
®
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4 Compressed air
4.1 Compressed air quality .......................................................................... 38

4.2 Supply pressure ..................................................................................... 38
4.3 Compressed air consumption of the separators OSD, OSE and OTC.. 38
®
Westfalia Separator
38 2058-9601-020 / 0211
4.1 Compressed air quality
• The compressed air must be free from impurities and dry.
4.2 Supply pressure

Recommended set-up of compressed air line per treatment system.
Fig. 33 OSD separators
• A supply pressure of 0.3 to max. 1.0 MPa is admissible.

• After the reducer station 0.3 MPa must still be available to the consumers.
• Note:
On OSD separators, a compressed air control unit is no longer included in the
standard scope of supply.
• If other pneumatic components are operated, the corresponding instructions
relating to air quality and air lubrication must be observed.
4.3 Compressed air consumption of the separators OSD, OSE and OTC
• The maximum compressed air consumption per separator is approx. 0.01
3
Nm /h.
®
Westfalia Separator
2058-9601-020 / 0211 39
5 Product lines
5.1 General .................................................................................................. 40

5.2 Pipe cross-sections ................................................................................ 40
5.3 Functional description ............................................................................ 40
5.4 Information on pressure monitoring ....................................................... 40
5.5 Piping ..................................................................................................... 42
5.6 Maximum suction head .......................................................................... 43
5.6.1 Pressure line .......................................................................................... 43
5.6.2 Pre-filter ................................................................................................. 44
5.7 Feed pump ............................................................................................. 44
5.8 Oil pre-heater ......................................................................................... 44
5.9 Installation examples ............................................................................. 45
5.9.1 Steam-heated plate heat exchanger with (PI controlled) control valve . 45
5.9.2 Steam-heated tubular heat exchanger with (PI controlled)
control valve ........................................................................................... 46
valve....................................................................................................... 47
control valve ........................................................................................... 48
5.10 Securing plate heat exchangers ............................................................ 49
5.11 Safety valve ........................................................................................... 50
®
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40 2058-9601-020 / 0211
5.1 General
• Pay special attention to section 1.3!
• The suction lines should be as short as possible to avoid pressure losses.
• The pipes must be installed with adequate clearance from the electronic
parts.
• Water pockets must be avoided! (water must be able to flow off freely).
• When different products are run through the same separator, it must be en-
sured that the corresponding product lines cannot be interchanged.
5.2 Pipe cross-sections

• All pipes, valves, fittings and instruments must be laid so that an insulation of
40 mm is possible.
• Dimensioning of the pipes is specified on the respective P&ID.
• The pipes can be selected with the aid of the following diagram. The specifi-
cations on the P&IDs have priority!
• Pipe resistances must be kept as low as possible.
• Taking into account the total pressure losses, the flow velocities must be
– between 0.5 m/s and < 1 m/s in suction lines,
– between 1 m/s and 3 m/s in pressure lines.
5.3 Functional description

The liquid is discharged from the separator by means of a pumping device, in
the following referred to as centripetal pump. At small capacities, the discharge
can be without pressure; in the case of larger capacities the centripetal pump
generates the required pressure to convey the liquid out of the separator
through the downstream lines by immersing more deeply into the liquid.
The pressure values can differ significantly. The following rule applies: The val-
ues are lower on small separators than on large separators.
Further influencing factors are capacity, system resistances (valve position, tank
position), product properties and process specifications.
5.4 Information on pressure monitoring

When the liquid is discharged from the separator under pressure, the operator
knows that the separator bowl is hydraulically closed.
A discharge pressure adjusts given a constant capacity or it is adjusted to the
desired value by throttling in the discharge.
In the standard application, the pressure sensor responds to falling discharge
pressure, an alarm is triggered via the control system. The control system can
also evaluate rising pressure and trigger an alarm.
Generally, the discharge pressure is set to 0.1 – 0.2 MPa. The pressure level
can deviate from this when separator size, capacity, product properties and
process specifications require. (for further information, see the order-specific
documentation)
®
Westfalia Separator
2058-9601-020 / 0211 41
A change in the discharge pressure may be caused by the following factors:

• Change in feed capacity
• Change in product data such as temperature, density, viscosity
• Change in discharge resistance
• Leakage at the separator bowl
This represents important information for the operator.
Selection diagram
Fig. 34
Q Flow
v Velocity in m/s
Example:
3
A flow rate of 5 m /h produces a velocity of 1.2 m/s with a nominal diameter of
40.
®
Westfalia Separator
42 2058-9601-020 / 0211
5.5 Piping
Fig. 35 Lubrication oil schematic
1 LO tank
• When separating lube oil, the return line of the 3/2-way valve can be led into
the product discharge line of the separator.
Fig. 36 Diesel oil schematic
1 DO tank
2 Service tank
• When separating diesel oil, the return line of the 3/2-way valve must be led
into the DO tank 1.
WS does not permit leading the return line into the suction side of the
pump!
®
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2058-9601-020 / 0211 43
Fig. 37 Heavy fuel oil schematic
1 Settling tank
2 Service tank
• When separating heavy oil, the return line of the 3/2-way valve must be led
into the settling tank 1.
5.6 Maximum suction head

• The suction head of the feed pump (gear pump) is max. 0.04 Mpa.
• The suction head of the feed pump (screw pump) is max. 0.05 MPa.
• The viscosity of the oil to be conveyed must be kept < 1 000 cSt, if necessary
by adequate pre-heating and trace heating.
• When dimensioning the suction line, it must be ensured that the total pressure
loss in the pipe does not exceed the maximum suction head of the pump.
• The maximum feed pressure in the suction line must not exceed 0.05 MPa.
5.6.1 Pressure line

• The pressure head of the feed pump is set to approx. 0.3 MPa.
• The pressure line from the feed pump via the pre-set valve, the pre-heater
and the 3/2-way valve to the separator must be kept as short as possible.
• When dimensioning the pressure line, it must be ensured that the total pres-
sure loss in the pipes does not exceed the maximum pressure head of the
pump.
®
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44 2058-9601-020 / 0211
5.6.2 Pre-filter
• The pre-filters are fitted in the suction line of the feed pump to protect it from
coarse impurities.
• During the installation, special attention must be paid to the operability.
• Use only strainers with a mesh width

of the strainer insert of 1 to 1.25
mm.
• Pay special attention to section 1.3!
Fig. 38
• Use only pre-strainers with a mesh

width of the strainer insert of 0.63
mm.
Fig. 39
5.7 Feed pump
To prevent the pre-heater from overheating,

• a pump post-running time must be programmed for pump units and product
pre-heating.
5.8 Oil pre-heater

• It must be installed so that there is no heat dissipation to the control cabinet.
To prevent a risk of accidents when venting due to discharging hot va-

pours and liquids,
• the discharge lines from vent valves must be laid at least to floor plate height.
• Discharge lines of safety valves must be laid so that there is no danger

of accident when the valve responds due to discharging liquid.
• The discharge line must be laid so that it can always be observed. It must not
be concealed by pipes, valves or other units!
®
Westfalia Separator
2058-9601-020 / 0211 45
• Steam traps
– must be fitted horizontally between two unions.
– should not be insulated to assure correct functioning.
– must be installed so that no condensate accumulation can occur on the pre-
heaters.
5.9 Installation examples

The following sections show installation examples for
– Tubular heat exchanger
– Steam-heated plate heat exchanger with (PI controlled) control valve
– Steam-heated tubular heat exchanger with (PI controlled) control valve
– Thermal oil-heated plate heat exchanger with (PI controlled) control valve
– Thermal-oil-heated tubular heat exchanger with (PI controlled) control valve
5.9.1 Steam-heated plate heat exchanger with (PI controlled) control

valve
Fig. 40
A Oil inlet 0.1 Spring safety valve

B Oil outlet 1.0 Plate heat exchanger
C Steam inlet 1.1 Resistance thermometer (PT 100)
D Condensate outlet 2.1 Strainer
2.2 Motor control valve
2.3 Ball float condensate trap
®
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46 2058-9601-020 / 0211
5.9.2 Steam-heated tubular heat exchanger with (PI controlled) control

valve
Fig. 41

B Oil outlet 1.0 Tubular heat exchanger
C Steam inlet 1.1 Resistance thermometer (PT 100)
D Condensate outlet 2.1 Strainer
2.2 Motor control valve
2.3 Ball float condensate trap
®
Westfalia Separator
2058-9601-020 / 0211 47
valve
Fig. 42

B Oil outlet 1.0 Plate heat exchanger
C Thermal oil inlet 1.1 Resistance thermometer (PT 100)
D Thermal oil outlet 2.1 Motor control valve
®
Westfalia Separator
48 2058-9601-020 / 0211

control valve
Fig. 43

B Oil outlet 1.0 Tubular heat exchanger
C Thermal oil inlet 1.1 Resistance thermometer (PT 100)
D Thermal oil outlet 2.1 Motor control valve
®
Westfalia Separator
2058-9601-020 / 0211 49
5.10 Securing plate heat exchangers
Assembly instructions for soldered

plate heat exchanger
• Prepare an assembly plate support
and weld it to the foundation.
• Fasten assembly plate 50 with
screws 70 and nuts 80 to the as-
sembly plate support.
The assembly plate must be in-
stalled vertically relative to the pipe
axis.
IMPORTANT:
Welding the assembly plate to the
support is not permitted.
• Fasten heat exchanger with gaskets
40 counterflanges 30, lock washers
20 and screws 10 to the assembly
plate.
• Attach the pipes to the counter-
flanges by tack-welding.
• Dismantle the heat exchanger and
gaskets.
• Completely weld the pipes to the
counterflanges.
• Finally, re-assemble the parts as per
instruction.
Fig. 44
A The illustrated channel steel must be provided by the shipyard.

B GEA Westfalia Separator recommendation as example channel steel ac-
cording to DIN1026-1-50.
IMPORTANT:
Distortion or warping or other stress of the soldered connection points must be
avoided!
Pipelines must be correspondingly arrested.
10 20 30 40 50 70 80
Pos./
type Allen screw Lock Groove- Gasket Plate Hex head Hexagon
washer faced screw nut
flange
ISO 4762 - DIN127 - 1 in - 32.92 x 3.53 352 x 125 x ISO 4017 - ISO 3032 -
M10 x 45 B10 SAE3000P (8 x) 12 M12 x 40 M12
B 10 (16 x) (16 x) SI (1 x) (2 x) (2 x)
(4 x)
ISO 4762 - DIN127 - 2 in - 56.74 x 3.53 563 x 290 x ISO 4017 - ISO 3032 -
M12 x 55 B12 SAE3000P (8 x) 12 M12 x 40 M12
B 45 (16 x) (16 x) SI (1 x) (2 x) (2 x)
(4 x)
®
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50 2058-9601-020 / 0211
5.11 Safety valve
Safety valve in vertical fitting posi-

tion
Fig. 45
• The safety valve outlet should be led

via a funnel (pos. “1”).
A discharge line is welded to the
funnel via which the medium can be
discharged.
IMPORTANT:
• Do not use galvanized compo-
nents and hoses.
Fig. 46
®
Westfalia Separator
2058-9601-020 / 0211 51
6 Solids tank
6.1 Recommended criteria for solids tank ................................................... 52

6.1.1 Tank vent ............................................................................................... 53
6.1.2 Set-up of the solids tank venting ........................................................... 54
6.2 Solids discharge lines ............................................................................ 55
6.2.1 Solids discharge lines with shut-off flap................................................. 56
6.2.2 Standard installation of shut-off flaps .................................................... 56
6.2.3 Installation recommendation for shut-off flaps ....................................... 57
6.3 Operating and dirty water discharge lines ............................................. 58
6.3.1 Separators of OSD and OSE ................................................................. 58
®
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52 2058-9601-020 / 0211
6.1 Recommended criteria for solids tank
Note:
This information does not apply to sludge transfer units on compact units.
• There should always be separate solids tanks for the lube oil and fuel sys-
tems.
• Tank heating should be installed in dependence of the viscosity or ambient
temperature.
• The general designs and constructions are subject to the valid regulations.
1 Monitoring
2 Venting
3 Tank heating
4 Utilizable volume
Fig. 47
Minimum solids tank volume

Volume Maximum utilizable volume
Separator model
[l] [%]
OSD 2 80 60
OSD 6 200 60
OSD 18 200 60
OSD 35 300 60
OSD 60 300 60
OSE 5 80 60
OSE 10 200 60
OSE 20 200 60
OSE 40 300 60
OSE 80 300 60
®
Westfalia Separator
2058-9601-020 / 0211 53
6.1.1 Tank vent

• In the case of one or more separators which are connected to a solids tank,
the nominal widths DN to be used are given in the table below:
Note:
Connect the tank vent to the on-board venting system.
Tank vent
Separators DN in mm
per solids tank
OSD 2 OSD 6 OSD 18 OSD 35 OSD 60
1 50 80 80 125 125
2 50 100 100 150 150
≥3 80 125 125 150 150
OSE 5 OSE 10 OSE 20 OSE 40 OSE 80

1 50 80 80 125 125
2 50 100 100 150 150
≥3 80 125 125 150 150
• In the case of a combination of separator models on one solids tank

– the total number of all separators must be taken as a basis
– and the nominal width of the largest model used.
The following criteria must be taken into consideration when venting the tank:
• Installation in accordance with the guidelines of the classification societies
• Controlled discharge of oil vapours
• An uncontrolled discharge of the sludge must be avoided.
• The vent lines must be laid so that a chimney effect develops.
• All possible loops in the vent lines must be stepwise.
®
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54 2058-9601-020 / 0211
6.1.2 Set-up of the solids tank venting
Solids tank with one separator

• The nominal width DN is given in the
table above (section 6.1.1).
Fig. 48
Solids tank with several separators

• The nominal width DN is given in the
table above (section 6.1.1).
Fig. 49
Solids tank with wash plates

A solids tank with wash plates is re-
quired when movements of the ship
cause faulty functioning of the level
monitoring.
• When using wash plates, each sec-
tion must be vented.
• The vent lines must be brought to-
gether.
Fig. 50
®
Westfalia Separator
2058-9601-020 / 0211 55
6.2 Solids discharge lines
• The solids discharge lines should

always be vertical if possible.
• The solids discharge must always
end 50 – 100 mm below the tank
top.
• The maximum level in the solids
tank must be monitored by means of
a float switch.
• The piping for the solids discharge
should be without reduction and with
vibration compensators.
• The length of 2 m may not be ex-
ceeded without trace heating.
Fig. 51
• If there is a deviation from the verti-

cal, an angle of 45° must not be ex-
ceeded.
Fig. 52
IMPORTANT:
• This piping arrangement is not ad-
missible!
Fig. 53
®
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56 2058-9601-020 / 0211
6.2.1 Solids discharge lines with shut-off flap

• A shut-off flap in the solids discharge line prevents the penetration of vapours
into a stationary separator during the desludging of another separator.
• If more than one separator is used for a sludge tank, a shut-off flap must be
installed in the sludge discharge at the shipyard.
• Shut-off flaps are not included in the standard scope of supply of GEA West-
falia Separator but can be ordered from GEA Westfalia Separator.
• CP units or modules equipped with a sludge tank supplied by GEA Westfalia
Separator and equipped with more than one separator are always delivered
with shut-off flaps.
6.2.2 Standard installation of shut-off flaps
Separators of OSD and OSE
Fig. 54
I Solids discharge III Tank vent

II Hood and frame drain IV Shut-off flap
• Discharges I, and III must be configured as illustrated in Fig. 57.

• See section 6.1.1, table for tank vent connection.
ATTENTION!
It must be ensured that the shut-off flaps are open during separator operation.
®
Westfalia Separator
2058-9601-020 / 0211 57
6.2.3 Installation recommendation for shut-off flaps
• The solids discharge must always

end below the tank top.
• For dimension X, see section 6.2,
Fig. 51.
I Shut-off flap
II Flange
III Pipe
IV Hose (supplied with separator)
V Solids tank cover
Fig. 55
Fig. 56
®
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58 2058-9601-020 / 0211
6.3 Operating and dirty water discharge lines

• The discharges for operating and dirty water can be conveyed into a separate
tank for oily water.
• The piping for the operating and dirty water discharge should be vertical,
without reduction and with vibration compensators. There is no upper length
limit.
IMPORTANT:
Operating and dirty water discharges may not be discharged into public
canals, draining ditches and waters!
6.3.1 Separators of OSD, OSE and OTC
• The water discharges must be sub-

merged under all conditions
(roll/pitch).
• Dimension h is:
– min. 50 mm for shipboard opera-
tion,
– min. 20 mm for stationary plants.
I Hood and frame drain

II Solids discharge
III Tank vent
Fig. 57
• When a siphon is installed, the

frame drain need not be submerged
below the minimum level because a
liquid seal is assured.
• Dimension h1 is given in the table
below.
I Solids discharge
II Hood and frame drain
III Tank vent
IV Siphon for hood and
frame drain
Fig. 58
®
Westfalia Separator
2058-9601-020 / 0211 59
Table for defining siphon length, dimension “h1”
Siphon length [mm]

Separator model
h1
OSD 6 / OSD 18 500
OSD 35 / OSD 60 800
OSE 5 500
OSE 10 500
OSE 20 500
OSE 40 800
OSE 80 800
OTC 2 –
OTC 3 –
OTC 5 –
OTC 10 –
OTC 20 –
®
Westfalia Separator
60 2058-9601-020 / 0211
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note
®
Westfalia Separator
2058-9601-020 / 0211 61
7 Electrical installation
7.1 Control cabinet ....................................................................................... 62

7.1.1 Electrical connection .............................................................................. 64
7.1.2 External voltages ................................................................................... 64
7.1.3 Shipboard operation .............................................................................. 65
7.1.4 Onshore operation ................................................................................. 65
7.2 Electro-magnetically compatible installation .......................................... 66
7.3 Valves .................................................................................................... 67
7.3.2 Terminal box .......................................................................................... 68
7.3.3 Separator with sensor bloc .................................................................... 69
7.4 Dual-purpose thermometer .................................................................... 70
7.5 Electrical installation of transmitters and electric motors ....................... 71
7.6 Electrical execution ................................................................................ 71
7.6.1 Earthing the separator ........................................................................... 72
7.6.2 Voltage equalisation of the separator .................................................... 72
7.6.3 Voltage equalization of the electric heater ............................................. 73
7.6.4 Voltage equalization of the foundation frame ........................................ 73
7.6.5 Voltage equalisation of the control cabinet ............................................ 74
7.7 Electric motors procured by the customer ............................................. 75
7.8 Installation and operation of control units .............................................. 76
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62 2058-9601-020 / 0211
7.1 Control cabinet
Control cabinet configuration
1 Lock
2 Control Unit D10
3 OFF/ON keys for separator
4 OFF/ON keys for feed pump
5 HAND/0/AUTOMATIC selector for
solids pump (option)
6 Main switch
Fig. 59 Front view
Fig. 60 Interior view
1 Isolating amplifier for analog output (option)

2 WMS (Water Content Monitoring System) relay, if provided
3 Full-motor-protection module
4 Interface relay
5 Auxiliary contactor
6 Main contactor
7 Current transformer
8 Power supply for PLC (Programmable Logic Control) and valves
9 Terminal Strip
10 Control transformer for heating and venting facilities (option)
11 Main switch
12 Control voltage transformer (option)
13 Motor protection switch
14 Safety outcut
®
Westfalia Separator
2058-9601-020 / 0211 63
Mounting example
1 Gasket 10,5x23x5
2 Threaded bolt M 8 (embedded
in the wall)
3 Washer
4 Rear panel of control cabinet
5 Washer
6 Wall
Fig. 61
• The control cabinet

– must be allocated to the corresponding separator by means of its designa-
tion.
– must be mounted on a frame or wall in the vicinity of the separator.
– conforms to enclosure IP 54.
• It must be possible to open the control cabinet door wide so that the door
latch can lock into place.
– it can be easily operated and observed.
– an ambient temperature of 50 °C (122 °F) is not exceeded. If necessary,
make sure there is an adequate supply of fresh air.
• If the control cabinet is mounted on a wall, a wall clearance of 20 m must be

observed to achieve a vibration-free fastening arrangement.
• Although buttons and switches and the electronic control unit are protected
against moisture by protective foil and door seal, the cabinet must neverthe-
less not be installed in an excessively humid environment or damp area.
• To keep the temperature inside the unit constant after commissioning, the
main switch should be kept turned on even when the separator is at a stand-
still.
®
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64 2058-9601-020 / 0211
7.1.1 Electrical connection

• The control unit is designed for a connected voltage as indicated on the
nameplate inside the control cabinet.
• In the case of a version without motor starter, the rated connection voltage is
115 VAC or 230 VAC which must be protected by a 6 A slow-blow fuse.
7.1.2 External voltages
– carry external voltage (even when the main switch is off!).
– can be identified by the orange coloured wiring.

– can be used in external control systems up to 250 VAC.
• A cross-section of 1.5 mm Cu is adequate for all control and interlocking
2
lines.
• The voltage-free contacts of the output modules
®
Westfalia Separator
2058-9601-020 / 0211 65
7.1.3 Shipboard operation

• For shipboard operation
– Only lines type "MGCH" according to DIN 89 158 may be used.
– All cables must meet the flame test requirements for bunched cables acc.
to IEC 60332-3 / IEEE 45-18.13.
– All cable materials must be free of halogens acc. to IEC 60754-1, no
toxicity acc. to 60754 and no corrosivity acc. to IEC 60754-2.
– All cables must have an approval of the relevant classification society.
– Insulating strength: 0.6/1KV
– GEA WSPN Standard: Nexans MPRX 0.6/1kV
– The standard control cabinets are equipped with plastic non halogen oil
resident. WS standart is “Ernst Heinrich GmbH”
– load and control lines can be laid jointly without clearance
• In the case of HFO separators in series operation, the signal exchange be-
tween the control cabinets as per the terminal diagram for the connecting ca-
ble must be taken into account (see section 7.2).
Cable glands for shipboard installation
Female ∅ Cable outer Earthing device +

Cable gland
thread [mm] Inner parts design
M 16 x 1.5 4 – 11 M 24 x 1.5
M 20 x 1.5 8 – 13 M 24 x 1.5
M 25 x 1.5 11 – 17 M 36 x 1.5
M 32 x 1.5 15 – 21 M 36 x 1.5
M 40 x 1.5 19 – 28 M 36 x 1.5
7.1.4 Onshore operation

• The local rules and regulations of the operator must be observed!
• for onshore operation
– Normally, "ölflex" cables are used and "NSSHÖU" for outside installation.
– commercially available cable glands can be used.
– separate cable routing must be used for the load and control lines.
• Cable entries with plastic or metal glands are admissible.
®
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66 2058-9601-020 / 0211
7.2 Electro-magnetically compatible installation

• The control cabinet is designed to be electro-magnetically compatible.
• The following must be taken into account with electro-magnetically compatible
installations:
– Earthing straps
– Voltage equalization
– Screening lines
– Separate line routing
– Use of erase elements in case of inductance.
In the case of HFO series operation, proceed in accordance with the following
wiring diagram:
Fig. 62
A Switch ON D Connecting terminals

B Control cabinet HFO No. 1 F Cable type
C Control cabinet HFO No. 2 E Customer shipboard installation
IMPORTANT:
• Use only data cable UNITRONIC-BUS-FD P L2/F.I.P (1 x 2 x 0.25 mm² +
Screen).
• Do not lay data cables directly next to load cables as this can cause prob-
lems with electromagnetic compatibility.
• Pay attention to the different software status on the C7 units:
– 1. unit has the MPI addresses 1 / 2
• Faulty or broken cable connections are displayed with error code no. 551.
• Check all connections.
®
Westfalia Separator
2058-9601-020 / 0211 67
7.3 Valves
Only original valves from GEA Westfalia Separator with integrated suppressor
diode and reverse battery protection in the connection head may be used in
filling, displacement and operating water lines.
7.3.1 Solenoid valve block
This diagram shows an original valve

block from GEA Westfalia Separator
which is used in filling, displacement
and operating water lines.
Fig. 63
Connections
A Connecting terminal + 24 V DC
B Connecting terminal + 0 V DC
C Earth
D Status LED
Fig. 64
®
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68 2058-9601-020 / 0211
7.3.2 Terminal box
All valves and monitoring instruments

are installed ready-to-connect on a
local terminal box at the separator.
• The connection to the control cabi-
net must be carried out by means of
a joint cable in accordance with the
adjacent connection diagram.
A Control cabinet
B Product discharge pressure
C “Self-Think” system
D Water sensor
E Circuit valve
F Water discharge valve
G Filling, displacement water valve
H Operating water valve
I Circulation valve
J Operating Water
K Filling, displacement water
Fig. 65
®
Westfalia Separator
2058-9601-020 / 0211 69
7.3.3 Separator with sensor bloc
Fig. 66
The components on the hood are wired to the terminal box.
®
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70 2058-9601-020 / 0211
7.4 Dual-purpose thermometer

• The dual-purpose thermometer is used
– to monitor the temperature of the dirty oil after the pre-heater and
– for local temperature indication.
ATTENTION!
• The dual-purpose thermometer is used only in conjunction with a C7 control
system.
Fig. 67 Fig. 68
• The dual-purpose thermometer must always be fitted before the 3-way piston
control valve.
• All sensors must be installed so that they are continuously flushed with oil.
®
Westfalia Separator
2058-9601-020 / 0211 71
7.5 Electrical installation of transmitters and electric motors

• The connection of motors and transmitters by means of cable loop enables
easy replacement and function testing of the components.
Example 1
Fig. 69
Example 2
Fig. 70
7.6 Electrical execution

The electrical execution must be in accordance with the following standards and
recommendations in so far as specifications and standards issued by the classi-
fication societies do not have to be met.
The applicable standards at GEA Westfalia Separator are

– the European standard EN 60 204 – Part 1 or
– VDE 0113 – Part 1
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Westfalia Separator
72 2058-9601-020 / 0211
7.6.1 Earthing the separator
• The separator must always be

earthed.
The earthing connection A is always

located on the motor side beneath the
motor flange.
Fig. 71
7.6.2 Voltage equalisation of the separator
Including the insulated installed sepa-

rator in the voltage equalisation of the
installation is done via the voltage
equalisation connection on the motor
side. This applies always.
If there is no protective conductor in

multi-core cables and leads (e.g. in the
armoured marine cable), the drive
motor must likewise be included in the
voltage equalisation.
The same applies for pump motors
and electric pre-heaters.
Fig. 72
The cross-section of the voltage

equalisation conductor, normally insu-
lated green-yellow, is dimensioned to
the largest external conductor on the
respective consumer.
In practice, table 1 in EN 60204-1 is

used for this.
GEA Westfalia Separator selects:

2 2
10 mm < S < 25 mm Cu
Fig. 73
®
Westfalia Separator
2058-9601-020 / 0211 73
7.6.3 Voltage equalization of the electric heater
Fig. 74
7.6.4 Voltage equalization of the foundation frame
• The foundation frame must be fitted

with a marked connecting bolt for
voltage equalisation by the cus-
tomer.
Fig. 75
Fig. 76
®
Westfalia Separator
74 2058-9601-020 / 0211
7.6.5 Voltage equalisation of the control cabinet

• The connection is via the PE-bar or terminal inside the cabinet to the frame
connection.
PE connection
Fig. 77
PE connection
Fig. 78
PE connection
Fig. 79
®
Westfalia Separator
2058-9601-020 / 0211 75
7.7 Electric motors procured by the customer

• When the motors are procured by the customer, they must have the following
specifications and comply with the following standards:
Design IM B5* according to IEC 34 – Part 7
Rating Classification according to IEC 72 – Part 2
Enclosure IM B5 according to IEC 34 – Part 5

Quality stage N * / S *according to IEC 34 – Part
Vibration severity 14,
Full key balanced * / Half key balanced *
50 Hz 60 Hz
Synchronous speed
3000 * / 1500 * 3600 * / 1800 *
Type of cooling 1C411 according to IEC 34 – Part 6
Flange dimensions according to IEC 72
Shaft dimensions according to IEC 72
Direction of rotation according to IEC 34 – Part 8
Insulation material class F according to IEC 34 – Part 1
PTC thermistors as full motor protection

• The PTC resistors mist be fitted in the end
Motor protection windings – one per strand.
• PTC resistors – temperature feelers which are
mounted on the winding package from the
outside are not acceptable!
Operating mode SI according to IEC 34 – Part 1
* dependent on separator model
ATTENTION!
Consequential damage on the separator caused by motors procured by
the customer cannot be accepted as a warranty claim by GEA Westfalia
Separator.
®
Westfalia Separator
76 2058-9601-020 / 0211
7.8 Installation and operation of control units
IMPORTANT:

– the control unit is not exposed to dust and aggressive atmosphere.
– the control unit is not installed in an excessively humid environment or
damp area.
– the sun cannot shine on the control panel or displays making operation and
observation more difficult.
– heating up of the control unit is avoided.
• Where appropriate, check screw-type and plug-type connectors for secure

contact.
• Connect thermostatically controlled cabinet heating to external voltage and
switch it on.
• The control cabinet heating must switch on before the temperature drops be-
low the dew point.
• Bedewing can occur during the night which is not good for electronic appara-
tus.
• Check that the line voltage and frequency conform to the connection data of
the control unit (see nameplate).
• Pay attention to admissible installation and operating data:
Voltage fluctuations +/- 10 % of the line voltage

Frequency fluctuations +/- 2 % of the line voltage
Ambient temperatures + 5 to + 45 °C (41 to 113 °F)
Atmospheric humidity max. 50 % at 40 °C (104 °F)
max. 90 % at 20 °C (68 °F)
Installation height above sea level up to 1000 m
Transport temperatures – 25 to + 55 °C (–13 to 131 °F)
ATTENTION!
Improper installation and operation discharges the supplier from the war-
ranty obligation.
®
Westfalia Separator
2058-9601-020 / 0211 77
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note
®
Westfalia Separator
78 2058-9601-020 / 0211
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note
®
Westfalia Separator
2058-9601-020 / 0211 79
®
Westfalia Separator
Phone +49 2522 77-0, Fax +49 2522 77-2488
Westfalia Separator
Mechanical Separation
Mineraloil Systems GmbH
Division
Instruction Manual
No.: 8555-9001-010
Edition: 1207
Designation: Control system for separators with self-cleaning bowl
Model: D10
Westfalia Separator
2 Mineraloil Systems GmbH
TRANSLATION OF THE ORIGINAL INSTRUCTION MANUAL

the documentation. They can be sent to
Westfalia Separator Mineraloil Systems GmbH
Werner-Habig-Str. 1
D-59302 Oelde
© Westfalia Separator
8555-9000-010/1207
Westfalia Separator
Mineraloil Systems GmbH 3
We s tfa lia S e p a ra to r
Min e ra lo il S ys te m s Gm b H
Mechanical Separation
Division
Type
............................................................................................
Type
Prüf-Nr.
............................................................................................
Control No.
Bemessungsspannung
......... V, 3/AC ................. Hz
Nominal voltage
Steuerspannung
.............. V AC ................. Hz ............... V DC
Control voltage
Volllaststrom
................... A
Full-load current
Bemessungsstrom
(größter Motor/Verbraucher)
................... A
Nominal current
(largest motor/consumer)
Kurzschlussausschaltvermögen Icn
................. kA
Short-circuit breaking capacity
Schaltplan-Nr.
.........................................................................
Wiring diagram No.
Programm-Nr.
.........................................................................
Program No.
Part-No.
.........................................................................
Part No.
A company of GEA Group
Installations- und Schutzmaßnahmen sind nach den Bestimmungen des VDE bzw.
des zuständigen EVU auszuführen.
Installation and protective measures are to be taken in accordance with national and
local electric rules and regulations.
This page must be filled in by the user.

Please enter the data from the nameplate.
8555-9000-010/1207
Westfalia Separator
For your safety

This avoids damage to the separator, the control system and other
equipment.
symbol -
mation which help to better understand the separator, the control sys-
tem or plant components and the processes.

tionally to the operation of the separator. The plant operator must en-
sure compliance with these regulations.
• When operating electrical apparatus, certain parts carry danger-

ous voltage.
Before working in electrical components, take adequate preventive
measures according to the national provisions (in Germany in accord-
ance with the rules and regulations of the VDE (Verein Deutscher El-
ektrotechnik / Association of German Electrical Engineering) or of the
local electric power company.
Non-compliance with the protective measures can result in serious
damage to persons or property.
Any work on electrical components may only be carried out by an au-
thorized electrician.
• Only qualified or authorized specialized staff may operate, main-

tain and repair the separator and the control system.
Corresponding training courses take place in the manufacturer’s plant
or are held on site by the manufacturer.

The instructions in the separator and control system and manuals
must be followed.
Problem-free and safe operation is conditional on correct transport,
storage, installation and assembly as well as careful operation and
maintenance.
in these manuals may not be carried out.
8555-9000-010/1207
Westfalia Separator
• Operate the separator only in accordance with agreed process

and operating parameters
• Maintain the separator

as specified in the separator manual.
• Carry out safety checks on the separator,

as described in the chapter "Safety precautions" in the separator man-
ual.
• Liability for the function of the machine passes to the owner.

Liability for the function of the machine passes unconditionally to the
owner or operator irrespective of existing warranty periods in so far as
the machine is improperly maintained or serviced by persons other
than Westfalia Separator service personnel or if the machine is not
applied in accordance with the intended use.
Westfalia Separator shall not be liable for damage which occurs as a
result of non-observance of the above. Warranty and liability condi-
tions in the Conditions of Sale and Delivery of Westfalia Separator are
not extended by the above.
8555-9000-010/1207
Westfalia Separator
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note
8555-9000-010/1207
Westfalia Separator
1.1 Preface................................................................................................... 10
1.2 Correct usage ........................................................................................ 11
1.4 Safety markings ..................................................................................... 13
1.4.1 Safety markings and their meaning ....................................................... 14
1.5 Operations on the control system .......................................................... 16
1.5.1 Demands on the operating and maintenance personnel ....................... 16
1.5.2 Spare part requirements ........................................................................ 17
1.5.3 Electrical installation .............................................................................. 17
1.5.4 Operation ............................................................................................... 18
1.5.5 Shut-down and “Emergency-Off” ........................................................... 19
1.5.6 Maintenance and repair ......................................................................... 20
1.6 Explosion protection .............................................................................. 21
1.6.1 Classification of the centrifuge / plant .................................................... 21
1.6.2 Obligations of the operator .................................................................... 22
1.6.3 Standards and guidelines ...................................................................... 22
1.7 Care instructions .................................................................................... 24
1.8 Storage .................................................................................................. 24
1.8.1 After delivery .......................................................................................... 24
1.9 Disposal ................................................................................................. 24
2 Description 25
2.1 Function ................................................................................................. 26

2.2 Performance features ............................................................................ 27
2.3 Areas of application ............................................................................... 27
2.4 Functional layout diagram...................................................................... 28
2.5 Technical data ....................................................................................... 29
2.5.1 Control Unit D10 .................................................................................... 29
2.5.2 Control cabinet ....................................................................................... 31
2.6 Digital inputs and outputs ...................................................................... 32
2.7 Analog inputs and outputs (4 – 20 mA) ................................................. 33
2.7.1 Special versions ..................................................................................... 33
2.8 Configuration ......................................................................................... 34
2.8.1 Front view .............................................................................................. 34
2.8.2 Interior view............................................................................................ 35
3 Operation 37
3.1 Getting acquainted with the operating elements ................................... 38

3.1.1 Function keys ......................................................................................... 39
3.1.2 System keys........................................................................................... 41
3.1.3 Softkeys F1 – F4 .................................................................................... 41
3.1.4 Parameter entries .................................................................................. 42
3.2 Switching-on the control unit.................................................................. 43
3.3 Password protection .............................................................................. 44
3.4 Program sequence diagram .................................................................. 45
3.5 Process data overview (Home) ............................................................. 46
3.6 User settings .......................................................................................... 50
3.6.1 Calling up user settings ......................................................................... 50
3.6.2 User timings ........................................................................................... 52
8555-9000-010/1207
Westfalia Separator
3.6.3 Timer lists 1 and 2 ................................................................................. 54

3.6.4 Counters ................................................................................................ 55
3.6.5 Analog inputs (AI) .................................................................................. 59
3.6.6 Analog outputs (AO) .............................................................................. 63
3.6.7 Input list.................................................................................................. 64
3.6.8 Output list ............................................................................................... 64
3.6.9 PID controller ......................................................................................... 65
3.6.10 Time recording ....................................................................................... 68
3.6.11 Alarm counters ....................................................................................... 70
3.6.12 Alarm memory ....................................................................................... 72
3.6.13 Maintenance .......................................................................................... 73
3.6.14 Volume (option) ..................................................................................... 74
3.6.15 Service information ................................................................................ 77
3.6.16 Date and time ........................................................................................ 78
3.6.17 Separator settings .................................................................................. 79
3.6.18 Contrast ................................................................................................. 84
3.6.19 Language ............................................................................................... 84
3.6.20 Speed monitoring (option) ..................................................................... 86
3.7 Changing the Micro Memory Card (MMC) ............................................. 88
3.8 Memory reset ......................................................................................... 89
3.8.1 Setting the jumper .................................................................................. 89
3.8.2 CPU reset .............................................................................................. 90
4 Maintenance and servicing 91
4.1 Accident prevention ............................................................................... 92

4.2 Removing faults ..................................................................................... 93
5 Installation and connection 95
5.1 Installation of the control system ........................................................... 96

5.2 Connecting the control system .............................................................. 97
5.3 Centralised control via potential-free contacts....................................... 98
8555-9000-010/1207
Westfalia Separator
1.1 Preface................................................................................................... 10
1.2 Correct usage ........................................................................................ 11
1.4 Safety markings ..................................................................................... 13
1.5 Operations on the control system .......................................................... 16
1.5.4 Operation ............................................................................................... 18
1.5.5 Shut-down and “Emergency-Off” ........................................................... 19
1.6 Explosion protection .............................................................................. 21
1.6.1 Classification of the centrifuge / plant .................................................... 21
1.6.2 Obligations of the operator .................................................................... 22
1.6.3 Standards and guidelines ...................................................................... 22
1.7 Care instructions .................................................................................... 24
1.8 Storage .................................................................................................. 24
1.8.1 After delivery .......................................................................................... 24
1.9 Disposal ................................................................................................. 24
8555-9000-010/1207
Westfalia Separator
1.1 Preface
Equipment documentation
taining and repairing the control sys-
tem must have read and understood
the documentation.
plete, kept near to the installation
and be readily accessible to the op-
erators. It must be available to the
operators at all times!
Fig. 1
Nameplate (inside the control cabi-

net)
• For possible further inquiries please
state:
– type (1)
– control no. (2)
• To ensure fast and correct pro-
cessing, please state when ordering
spare parts:
– type (1)
– control no. (2)
– circuit-diagram no. (3)
Fig. 2
8555-9000-010/1207
Westfalia Separator
1.2 Correct usage

The control system
• is used to ensure automatic ejection and process monitoring of mineral oil
separators of the OSD and OSE series.
• is rated in accordance with the method of application of the separator agreed
with Westfalia Separator. Refer to the data sheet and contractual agreements.
The electronic control system triggers total ejections of the bowl at adjustable in-
tervals with or without displacement of the liquid from the bowl.
The following ejections can be selected for the separators stated:
– Partial ejections
Partial ejection of the bowl means partial emptying of the solids space of
the bowl. The product feed is shut off during partial ejection.
– Total ejections
In the case of a total ejection, virtually the complete bowl content is emptied
and collected in the solids vessel after closing the product valve and draw-
ing off the residual liquid.
Never initiate a total ejection when the separator is vibrating strongly
(bowl unbalance)!
– Pre-selectable partial ejections followed by a total ejection
For perfect clarifying efficiency and low ejection losses on the separator, the
time-dependent program cycle requires the solids content in the feed material
not to vary too much.
The separators with the UNITROL system have two inbuilt monitoring functions:
– WMS (Water content Monitoring System)
– SMS (Sludge Space Monitoring System)
Separators of the D / E generation can be upgraded for one-stage WMS/SMS
operation.
For details concerning specific functions refer to the corresponding chapters of
this manual.
Intended use involves

• adhering to these safety instructions and to the instruction manuals for the
control system and for the separator
• paying attention to safety markings in/on the control cabinet
• adhering to the data on the nameplate, e.g. the rated voltage
The contractually agreed conditions agreed with Westfalia Separator on the in-
tended use of the control system must be passed on to the operating personnel
by the plant operator.
Any operating mode deviating from this is not intended use and can result
in severe damage to property and persons!
8555-9000-010/1207
Westfalia Separator

Any use that deviates from the intended use is considered to be non-
compliant.
The control system may not be operated by:

• Persons who have not read and understood these basic safety precautions.
• Persons who have not read and understood the instruction manuals of the
control system and of the separator.
• Persons who have not been briefed on proper and correct operation.
• Persons who have not been adequately trained.
• Persons who have not reached the minimum age of 18 years.
The separator may not be operated:

• while maintenance and repair work is being done on the separator plant
• in case of insufficient air or water supply
• in case of impermissibly low supply voltage
• by persons who are not adequately trained.
• when the control system is operated with spare parts which do not come from
Westfalia Separator.
Non-compliance with the intended use

• can cause severe damage to the control system, the separator and other
plant components!
• can endanger the operator and other persons!
8555-9000-010/1207
Westfalia Separator
1.4 Safety markings

The safety markings (adhesive and plastic labels) are attached to all control sys-
tems on the front panel and inside the corresponding control cabinet in such a
way that they are clearly visible.
All safety markings on the control system and plant components must always be
in perfect condition.
Fig. 3 Safety markings on a control unit (example)
Safety markings
1 Configuration plan plates
2 Electrical markings
3 Warning pictograms
4 Maker's nameplate
5 Nameplate
The texts and part numbers of the safety markings change depending on the
languages required by the customer.
8555-9000-010/1207
Westfalia Separator

The following safety markings are attached inside/onto the control cabinet as
adhesive labels.
Before carrying out work, dis-

connect power to all compo-
nents of the monitoring system!
and unintended start-up of the separa-
tor!

separator and electrical plant com-
ponents:
• Make sure the separator is at a
standstill.
Fig. 4 • Switch off all electrical appliances
from being accidentally switched on.
Danger due to electrical voltage!

Before working on electrical con-

trol/plant components:
via the main switch.
Fig. 5
CAUTION:
Th e p a rts m a rke d in th is wa y c a n c a rry vo lta g e e ve n wh e n th e m a in
s witc h is o ff!
• Lock the separator/plant to prevent it from being accidentally switched on.
• Take adequate preventive measures according to the national provisions (in
Deutscher Elektrotechnik / Association of German Electrical Engineers) or of
the local electric power company.
specialists).
P ic to g ram s with wa rnin g te xt

Pictograms can be meaningfully supplemented as illustrated in the two following
examples:
– with warning text (Voltage is also present . . .),
– with signal word (ATTENTION!) and warning text.
8555-9000-010/1207
Westfalia Separator
Be i a u s g e s c h a lte te m S o u s te n s io n m ê m e
Danger through external voltage!
Ha u p ts c h a lte r e n p o s itio n d ’a rrê t d e
u n te r S p a n n u n g ! l’in te rru p te u r p rin c ip a l !
Vo lta g e a ls o p re s e n t Co n e l in te rru p to r
Voltage also present when main switch
wh e n m a in
s witc h is tu rn e d o ff!
p rin c ip a l d e s c o n e c ta d o s e
e n c u e n tra b a jo te n s ió n !
is turned off!
CAUTION:
The circuits marked in this way can
switch is off!
Fig. 6 Example 1
ACHTUNG! Danger through external voltage!

Auc h b e i a us g e s c ha lte te m
Ha up ts c ha lte r kö nne n
o ra ng e fa rb ig e Le itung e n
unte r S p a nnung s te he n.
ATTENTION!
ATTENTION! Also in case of switched off main isola-
Als o in c a s e o f s witc he d o ff
m a in is o la to r o ra ng e c o lo ure d c o re s
tor orange coloured cores can be un-
c a n b e und e r vo lta g e . der voltage.
ATTENTION!
Lo rs q u e le c o m m uta te ur p rinc ip a l
e s t é te int le s file s o ra ng e
p e uve nt ê tre s o us te ns io n. CAUTION:
switch is off!
Fig. 7 Example 2
No te :
Orange coloured leads are fitted as standard at Westfalia Separator.
Different colour leads can be fitted if requested by the customer!

earth.
Fig. 8
8555-9000-010/1207
Westfalia Separator
1.5 Operations on the control system
The control system works reliably, pro-

vided that it is operated and main-
tained in accordance with our operat-
ing instructions.
Fig. 9

• Electrical installation
• Operation
• Shut-down and “Emergency-Off”
• Maintenance and repair

Operating, maintaining or repairing the separator, the control system or the sep-
arator plant requires specialized knowledge!
CAUTION!

who
ing.
The operator of the separator, the control system or the separator plant
Westfalia Separator offers an extensive range of training and advanced training

courses. For more in-depth information, please check back with Westfalia Sepa-
rator or one of their authorised agencies.
8555-9000-010/1207
Westfalia Separator

Separator.
– safety risks,
ranty claims.

cian!
installation guidelines of Westfalia
Separator.
Fig. 11

– Low-voltage guideline 73/23/EWG
– Electro-magnetic compatibility 89/336/EWG.
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1.5.4 Operation
• Refer to chapter “operation”.

• Note nameplate.
Check the rated and control voltage
for conformity with the connection
data of the control system.
Fig. 12
When unusual noises or vibrations oc-

cur on the separator:
• Immediately shut down the separa-
tor with filled bowl via “emergency-
off”.
• Never trigger a bowl ejection!
• Evacuate the room.
• Do not re-enter the room until the
centrifuge has come to a standstill.
Fig. 13
• The bowl is not allowed to run with-

out liquid supply for more than 15
minutes, as otherwise it would result
in overheating of the bowl material.
For energy plants:

• Activate the cooling-water program
(see section 3.6.17 – Separator set-
tings).
• Activate automatic shut-down (see
section 3.6.17 – Separator settings).
Fig. 14
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1.5.5 Shut-down and “Emergency-Off”

In order to be able to be switch off all drives in a hazardous situation or in the
case of abnormal operating states, the control cabinet – depending on the ver-
sion – is equipped with:
– an emergency-off switch or
– a min switch with emergency-off function.
The separator is shut down by means of external and internal emergency-off
switches while performing two total ejections.
When the main switch with emergency-off function is activated, power is cut off
to the entire control system. There will be no bowl ejection.
Note:
Provided the separator is equipped accordingly, the shut-down procedure can
be accelerated by a pneumatic brake and safety-water function.
• For shut-down refer to the chapter

"Operation" of the start-up and shut-
down manual.
Fig. 15
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1.5.6 Maintenance and repair

Timely maintenance of the control system and the replacement of worn or dam-
aged plant components is essential to ensure safe operation.
Use only genuine spare parts from Westfalia Separator. Otherwise, safety
risks may arise (see section 1.5.2).
Maintenance and repair work may only be carried out to the extent described in
this instruction manual.
Maintenance and repair work not described in this manual may only be
carried out by the manufacturer or by "repair shops" authorized by the
manufacturer.
We recommend having the control system regularly checked by our specialists.
These checks help to maintain the operating safety and avoid unexpected
downtime.
Before carrying out maintenance

and repair work:
CAUTION! Risk of injury due to

electrical voltage and unintended
start-up of the separator!

standstill!
Possibilities for checking standstill
are described in the separator man-
ual.
Fig. 16
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1.6 Explosion protection
• Strictly adhere to the prevailing local

rules and regulations for operating in
potentially explosive areas.
An area is "potentially explosive"
when there is (or must be expected)
an explosive atmosphere in such a
volume that specific preventive
measures concerning design, con-
struction, and the use of centrifuges
and control systems are required.
Fig. 17
• The operation of centrifuges / control systems in "zone 0" areas, i.e.

where a dangerous explosive atmosphere is prevailing continuously or
for long periods or frequently, is not permitted!
• Operation of the centrifuges / control systems in
– areas of “zone 1”, i.e. in areas in which dangerous explosive atmosphere is
occasionally present,
– areas of “zone 2”, i.e. in areas in which dangerous explosive atmosphere
are rarely and briefly present,
is only admissible when the centrifuge / control system is equipped for use in
explosion-hazarded areas.
• Centrifuges installed in explosion-hazarded rooms can be operated by means
of a control panel installed in the vicinity of the centrifuge. The control system
is then installed outside the explosion-hazarded room.
• Only units designed for application in "ex" zones are allowed to be operated in
potentially explosive areas.
• All the electrical apparatus of the centrifuge/plant, i.e. motor controls, valve
controls, electric heaters, heater control units, electrically operated valves
must be protected accordingly or, if in standard design, must be installed in a
separate room outside the explosion-hazarded area.
• Supervisory equipment on the centrifuge such as pressure guards or transmit-
ters, flow detectors and temperature switches, pressure switches, must be
connected to intrinsically safe Eex(i) electric circuits.
• In the area close to the centrifuge/control system, take the preventive
measures provided under "primary" explosion protection” (ventilation, etc.).
• Carry out voltage equalization before operating the centrifuge / control sys-
tem.
1.6.1 Classification of the centrifuge / plant

The centrifuge/plant complies with the requirements of Group II, Equipment
Category 3 in accordance with the Directive 94/9/EG. The respective tempera-
ture class is specified in the technical documents.
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1.6.2 Obligations of the operator

The operator
• must assess the explosion risks and carry out the zone classification.
• must ensure that the centrifuge/installation is correctly erected and tested be-
fore commissioning.
• is responsible for the safety aspects of his centrifuge/installation.
The correct and proper condition of the centrifuge/installation must be main-
tained by regular testing and maintenance.
1.6.3 Standards and guidelines

The following standards, guidelines and regulations must be observed when us-
ing equipment in explosion-hazarded areas:
• Directive 94/9/EG (ATEX 95)

Equipment and protective systems for correct usage in explosion-hazarded
areas.
This Directive describes fundamental safety requirements and test proce-
dures for application outside of explosion-hazarded areas, which, however,
with regard to explosion hazards, are necessary for the safe operation of
equipment and safety systems or contribute to it.
• Directive 1999/92/EG (ATEX 137)

Protection of safety and health of the employees when working in explosion-
hazarded areas.
This Directive is directed at the operator and contains, among other things,
the necessary specifications and definitions for zone classification required for
assessment.
• EN 1127-1
Explosive atmospheres – explosion protection – Part 1 Fundamentals and
methodology
• EN 50 014
General provisions
• EN 50018 or IEC 60 079-1

Electrical apparatus for explosion-hazarded areas – flameproof enclosure “d”
Basic principle:
Parts which can ignite an explosive atmosphere are incorporated in a housing
which, in the event of an explosion of an explosive mixture, withstands the
pressure and which prevents transfer of the explosion to the atmosphere sur-
rounding the housing.
Main application:
Switching devices and switchboards, control switches and display units, con-
trol systems, motors, transformers, heating devices, lamps
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• EN 50019 or IEC 60 079-7

Electrical apparatus for explosion-hazarded areas – type of protection “e”
Basic principle:
Here, additional measures are implemented in order to increase the safety
margin to prevent the possibility of inadmissibly high temperatures and the
occurrence of sparks and arcs in the inside or at the outside of components of
electrical apparatus which do not otherwise occur in normal operation.
Main application:
Terminal and connector boxes, control boxes for fitting ex-components which
have a different type of protection and lamps.
• EN 50020 or IEC 60 079-11

Electrical safety for explosion-hazarded areas – intrinsically safe “i”.
Basic principle:
The apparatus used in explosion-hazarded areas contains only intrinsically
safe circuits. A circuit is intrinsically safe when no spark and no thermal effect
which occur under defined test conditions (which include normal operation
and certain error conditions) can cause ignition of a certain explosive atmos-
phere.
Main application:
Measuring and control technology, communication technology, sensors, actu-
ators.
• EN 60079-10 or VDE 0165 – Part 101

Electrical apparatus for explosion-hazarded areas -
Part 101 “Classification of the explosion-hazarded areas”
• EN 60079-14 or VDE 0165 – Part 1

Electrical installations in explosion-hazarded areas
• EN 60079-17 or VDE 0165 – Part 10

Part 10 “Testing and maintenance of electrical installations in explosion-
hazarded areas”
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1.7 Care instructions
ATTENTION!
The surface of the control unit (display, keypad) must not be cleaned with ag-
gressive or acidic media (pH 6-8, tenside content < 5 %, aroma-free, ethanol-
free).
1.8 Storage
ATTENTION!
Improper and incorrect storage of the control system can damage or de-
stroy its components.
Store accessories like spare parts and tools properly!
• The control unit and accessories must be stored dry, dust-free, vibration and
frost-free.
IMPORTANT: Outdoor exposure is not admissible!
• Protect from excessive heat!

Recommended storage temperature: + 5 to + 45 °C (41 – 113 °F)
1.8.1 After delivery

If the control system is not installed immediately after arrival,
• store the control system in its original transport packaging.
Recommended storage temperature: + 5 to +50 °C (41 – 122 °F)
IMPORTANT:
A storage time of more than 12 months of the control system is only allowed
after consulting the manufacturer.
1.9 Disposal
When the equipment is no more useful or the control system has reached the
end of its service life, the operator will be responsible for appropriate, envi-
ronmentally friendly disposal of its components and materials such as
– metal,
– caoutchouc and rubber
– plastics,
– glass,
– electric and electronic apparatus.
ENVIRONMENTAL PROTECTION!
Be sure to adhere to applicable environmental protection legislation!
More information on disposal matters can be obtained from local authorities.
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2 Description
2.1 Function ................................................................................................. 26

2.2 Performance features ............................................................................ 27
2.3 Areas of application ............................................................................... 27
2.4 Functional layout diagram...................................................................... 28
2.5 Technical data ....................................................................................... 29
2.5.1 Control Unit D10 .................................................................................... 29
2.5.2 Control cabinet ....................................................................................... 31
2.6 Digital inputs and outputs ...................................................................... 32
2.7 Analog inputs and outputs (4 – 20 mA) ................................................. 33
2.7.1 Special versions ..................................................................................... 33
2.8 Configuration ......................................................................................... 34
2.8.1 Front view .............................................................................................. 34
2.8.2 Interior view............................................................................................ 35
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2.1 Function
The illuminated four-line LC display provides information on the functional condi-
tions or troubles prevailing on the separator and - depending on program ad-
justment - visualises the corresponding process data.
Besides the control cabinet and the control unit, the control system comprises
all complete line fittings which, due to built-in electrically actuated equipment,
are subject to the control or supervision by the control system. These include:
– dirty-oil supply
– water supply
– operating-water connection
With UNITROL, they also include
– circulation and water discharge valve
– water detector (WMS sensor)
– pressure transmitter for the bypass line in SMS mode
On special order (optional):

– PT100 sensor in a two-wire circuit for min./max monitoring in the dirty oil
supply line
– level switch for monitoring the water discharge
– process-dependent control of an external feed pump
– level switch for monitoring the solids vessel
– min./max level switch for controlling a solids pump
– klaxon for audible alarm-signalling
The standard control system is designed for individual control of centrifugal
separators or clarifiers.
If required, in case of two-stage HFO treatment, series operation can be prese-
lected. For this purpose the piping between the separators will have to be laid
out accordingly, in order to connect the MPI interfaces of at least two control
systems.
The control system is built into the door of the control cabinet ready to be
hooked up and programmed for the required control task.
The operator is not authorized to carry out program modifications.
The operator can make the following settings by means of the keypad:
– machine-specific program selection
– timer value settings
– counter value settings
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2.2 Performance features

The control unit features the following:
– display for machine monitoring and operation
– function keys with LED status signal
– control voltage 24 V
– high operational reliability
– long service life
– user program on Micro Memory Card (MMC)
2.3 Areas of application
Application Description
Single or serial (-91-) The separator is run in single or series opera-
tion (-91-).
Single or series (-01-) The separator is run with activated Water Con-
tent Monitoring System (-01-) (for more details
(Water Content Monitoring
refer to separator manual)
System)
Single or series (-02-) The separator is run in single or series opera-
tion (-01-).
Single or series (-01/36-) The separator is used for heavy fuel oil treat-
ment, with activated Water Content Monitoring
(WMS/SMS - HFO)
System (-01) and Solids Space Monitoring
System (-36-).
Single or series (-01/96-) The separator is used for lube-oil treatment,
with activated Water Content Monitoring Sys-
(WMS/SMS - LO)
tem (-01) and Solids Space Monitoring System
(-96-).
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2.4 Functional layout diagram
Fig. 18
A Water
B Product discharge
C Product feed
1 Water pressure reducer

2 Feed assembly with solenoid valve for filling-, displacement-, and oper-
ating water
3 Control system and motor starter for separator
- Motor starter for feed pump
- Motor starter for solids pump
4 Terminal box (fitted to separator)
5 Water detector (WMS sensor)
6 Circuit valve
7 Pressure transmitter for solids-space monitoring
8 Water discharge valve
9 Pneumatic 3/2-way valve with manual override and solenoid valve for
control air (built into product feed to separator)
10 Pressure transmitter PSL for product discharge
11 Pressure transmitter PSH for product discharge
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2.5 Technical data
2.5.1 Control Unit D10
Technical data
Dimensions 215 x 165 x 88 mm
(width x height x depth)
Installation / cutout dimensions 202 x 152 mm (tolerance +1 mm)
Weight 1.35 kg
Display, LED background illumina- LED-backlit 4-line LCD display, each line
tion with 20 digits and 5 mm high
Keypad Foil-protected keyboard,
23 keys with 11 integrated LEDs
Interfaces Standard MPI port for PG and network in-
tegration, P-bus for S7 extension modules
Supply voltage DC 24 V, range DC 20,4; DC 28.8 V
Reverse-polarity protected yes
Voltage cut-off > 20 ms
Current consumption (In) 2.4 A
Integrated RAM 48 kByte
Storage memory Plug-in Micro Memory Card (MMC)
Backup Ensured by Micro Memory Card (MMC) no
battery needed.
Configuration software Step 7, Version 5.1 and later; Service
Pack 4
HMI software Integrated in Step 7
Inputs 24 digital, DC 24 V
4 analog, 4-20 mA / 0-10 V
1 PT 100
Outputs 16 digital, 0.5 A each, sum current 4 A
2 analog, 4-20 mA
Safety standard DIN EN 61131-2/IEC 61131-2
Enclosure Front of unit: IP 65 according to
IEC 60529, NEMA 4X
Housing: IP 20 according to IEC 60529
Electromagnetic compatibility A according to EN 55011
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Technical data
Climatic conditions Approved according to IEC 60068-2-1,
IEC 60068-2.2
Operation: 0 - 55 °C (32 - 131 °F) for verti-
cal installation
Storage: -20 °C to +70 °C (-4 to 158 °F)
Humidity: 5 - 95 % at 25 °C (77 °F)
Mechanical ambient conditions Vibrations during operation: Approved ac-
cording to IEC 60068-2-6, IEC 60068-2.6
Vibrations during storage/transport:
10 to 58 Hz, amplitude 0.075, 5 - 9 Hz
Shocking during operation: Half-sine:
150 m/s2 (15 g), 11 ms, 18 shocks
Shocking during storage/transport:
250 m/s2 (25 g), 6 ms, 1000 shocks
Fire resistance Edge connectors: FV2 according to IEC
60707
Headers: FV0 according to IEC 60707
Approvals CE (EC Directive EMV 89/336/EWG)
UL (Underwriters Laboratories UL 508)
CSA (Canadian Standard Association
C22.2 No.142)
Prototype technical- release tests GL (Germanischer Lloyd)
/ classification societies LRS (Lloyds Register of Shipping)
DNV (Det Norske Veritas)
BV (Bureau Veritas)
ABS (American Bureau of Shipping)
RINA (Registro Italiano Navale)
NK (Nippon Kaigi Kyokai)
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2.5.2 Control cabinet
Technical data
Connection voltage 115/230 V AC (±10 %) reversible
Frequency 50 to 60 Hz
Max. power consumption 100 VA
Control voltage 24 V DC
Lead-in wire fuse 16 A (slow-blow fuse)
Ambient temperature 0 to 55 °C (32 to 55.00 °C)
Housing Painted sheet steel, RAL 7032
Special design: stainless steel
Enclosure IP 55 (if appropriately fitted according to
chapter 5: "Installation and connection")
Dimensions 380 x 600 x 350 mm
(width x height x depth)
Cable entry from below, through cable glands
Electrical execution according to EN 60204-1 (lead-colour coding optional,
upon agreement)
Ambient conditions. 3C2 according to EN 60721-3-3
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2.6 Dig ital in p u ts a n d o utpu ts
Designation Connection Function Terminal

Digital inputs DI 0.0 Separator in operation 1X2. 01/02
(DI) DI 0.1 Separator Fault 1X2. 03/04
DI 0.2 Spare –
DI 0.3 Spare –
DI 0.4 Spare –
DI 0.5 WMS-UNITROL 1X2. 11/12
DI 0.6 Spare –
DI 0.7 LSHH – solids vessel 1X2. 15/16
DI 1.0 Feed pump “Operation” 2K2 19/20
DI 1.1 Feed pump “Fault” 2Q2 21/22
DI 1.2 Solids pump “Operation” 5K1 23/24
DI 1.3 Solids pump “Fault” 5Q1 25/26
DI 1.4 LSH Solids vessel, for pump start 1X2. 27/28
DI 1.5 LSL Solids vessel, for pump stop 1X2. 29/30
DI 1.6 Vibration stage 1 1X2. 31/32
DI 1.7 Vibration stage 2 1X2. 33/34
DI 2.0 - DI 2.5 Spare –
DI 2.6 Limit switch, steam valve 1X2. 73/74
DI 2.7 Emergency-Off 3K1
Digital outputs DO 0.0 Product valve 1X2. 41/42
(DO)
DO 0.1 Water valve 1X2. 43/44
DO 0.2 Operating water valve 1X2. 45/46
DO 0.3 Steam valve / heater interlocking (option) 1X2. 47/48
DO 0.4 "UNITROL" circuit valve 1X2. 49/50

DO 0.5 "UNITROL" water discharge valve 1X2. 51/52
DO 0.6 Lamp test (option) –
DO 0.7 Collective alarm 1K11/1X2. 67/68
DO 1.0 Separator “Off” 1K12
DO 1.1 Feed pump “Off” 1K13
DO 1.2 Solids pump “Off” 1K14
DO 1.3 TSL (option) 1K15
DO 1.4 TSH (option) 1K16
DO 1.5 Brake (option) 1K17
DO 1.6 PID – open (option) 1K18
DO 1.7 PID – closed (option) 1K19
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2.7 An a lo g in p u ts a n d o u tp u ts (4 – 20 m A)
Designation Connection Function Terminal

Analog inputs AI 01 Motor current and ejection monitoring 1U3 6/7
(AI)
AI 02 Clean-oil discharge 1U2 12+/13-
AI 03 SMS transmitter / water discharge 1X2. 61/63/SC
AI 04 PID controller for product temperature 1X2. 76/77
PT 100 PT-100 product temperature 1X2. 78/79
Analog outputs AO 0-I Motor current 1X2. 93/94/SC
(AO)
AO 1-I Temperature 1X2. 91/92/SC
2.7.1 Special versions

Special versions differing from the one described in this manual are available:
– The housing can have other dimensions.
– The housing can be made of stainless steel.
– Individual components of the control system can be integrated in a compact
cabinet (e.g. with separator motor control etc.) or in a central control sys-
tem.
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2.8 Configuration
The construction can vary depending on the delivery scope.
The control system is assembled ready for use, wired ready for hook-up and
conforms to the regulations of EN 60204.
2.8.1 Front view
Fig. 19
1 Lock
2 Control Unit D10
3 OFF/ON keys for separator
4 OFF/ON keys for feed pump
5 HAND/0/AUTOMATIC selector for solids pump (option)
6 Main switch
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2.8.2 Interior view
Fig. 20
1 Isolating amplifier for analog output (option)

2 WMS (Water Content Monitoring S ystem) relay, if provided
3 Full-motor-protection module
4 Interface relay
5 Auxiliary contactor
6 Main contactor
7 Current transformer
8 Power supply for PLC (Programmable Logic Control) and valves
9 Terminal strip
10 Control transformer for heating and venting facilities (option)
11 Main switch
12 Control voltage transformer (option)
13 Motor protection switch
14 Safety cut-out
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Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note
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3 Operation
3.1 Getting acquainted with the operating elements ................................... 38

3.1.1 Function keys ......................................................................................... 39
3.1.2 System keys........................................................................................... 41
3.1.3 Softkeys F1 – F4 .................................................................................... 41
3.1.4 Parameter entries .................................................................................. 42
3.2 Switching-on the control unit.................................................................. 43
3.3 Password protection .............................................................................. 44
3.4 Program sequence diagram .................................................................. 45
3.5 Process data overview (Home) ............................................................. 46
3.6 User settings .......................................................................................... 50
3.6.1 Calling up user settings ......................................................................... 50
3.6.2 User timings ........................................................................................... 52
3.6.3 Timer lists 1 and 2 ................................................................................. 54
3.6.4 Counters ................................................................................................ 55
3.6.5 Analog inputs (AI) .................................................................................. 59
3.6.6 Analog outputs (AO) .............................................................................. 63
3.6.7 Input list.................................................................................................. 64
3.6.8 Output list ............................................................................................... 64
3.6.9 PID controller ......................................................................................... 65
3.6.10 Time recording ....................................................................................... 68
3.6.11 Alarm counters ....................................................................................... 70
3.6.12 Alarm memory ....................................................................................... 72
3.6.13 Maintenance .......................................................................................... 73
3.6.14 Volume (option) ..................................................................................... 74
3.6.15 Service information ................................................................................ 77
3.6.16 Date and time ........................................................................................ 78
3.6.17 Separator settings .................................................................................. 79
3.6.18 Contrast ................................................................................................. 84
3.6.19 Language ............................................................................................... 84
3.6.20 Speed monitoring (option) ..................................................................... 86
3.7 Changing the Micro Memory Card (MMC) ............................................. 88
3.8 Memory reset ......................................................................................... 89
3.8.1 Setting the jumper .................................................................................. 89
3.8.2 CPU reset .............................................................................................. 90
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3.1 Getting acquainted with the operating elements
6 1 2
Westfalia Separator AG
F1 F2 F3 F4
M
1 2 3 4 5
Process Process SERIES ESC

STOP START 1 2 Help
6 7 8 9 0
PID Home
EDIT ENTER
DIR
5 4 3
Fig. 21
The D10 control unit is built into the door of the control cabinet. The operating
interface consists of:
1 Soft keys F1 – F4 (depending on the current display)
2 Text display
3 System keys
4 Function keys
Numerical values can be entered when the EDIT key is actuated.
5 Status and fault indication
6 Operating mode switch (CPU start/stop)
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3.1.1 Function keys

The function keys have a global function: The actions which can be triggered
are independent of the text shown in the display. They each incorporate an LED
which gives information on the state of the respective function.
Key Key designation Description

Separating program “Off” In separation mode, this key closes the feed valve and triggers
a bowl ejection.
On OSC/OSD separators two total ejections are performed au-
tomatically.
The LED lights up when the ejections are being performed.
Separating program “On” This key starts the separating program.
The feed valve is opened when the ejection program has end-
ed.
When the separating temperature falls below its min. level or
when level switch “LSHH solids vessel" responds, no program
start is possible.
The LED lights up when the ejection or separating program is
active.
Lamp test This key launches a function test of the LEDs incorporated in
the keys and of external signal lamps, if provided.
The LEDs for status and fault signalling are not tested.
Series operation When running HFO separators in series, two control systems
can be preselected for this mode within an MPI network. To ac-
tivate series operation, actuate the "SERIES" key on both con-
trol units.
The LED lights up when series operation is active.
Home/DIR 1. Jumping directly to the process page
(see chapter. 3.5 ".Process Data Overview (Home)")
2. Jumping directly to the user settings
(see chapter 3.6 “User settings")
Fault message page This key is to call up the page giving an overview of pending
fault signals, i.e. the alarm memory.
For a pending alarm signal, a remedy catalog can be retrieved
after having acknowledged with the ENTER key.
When the LED is flashing, information on current remedy opera-
tions can be checked by actuating the F1 key.
The LED will flash as long as a fault signal is queued.
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PID controller Provided the plant is equipped accordingly, product feed and
temperature control can be activated while the “PID controller”
key is switched on.
The LED lights up when the control system is in automatic
mode.
For testing operations, first switch off the control system by
means of the “PID controller” key. In the corresponding screen
menu (see chapter 3.6.9 “PID control”) close/open the motor
control valve by means of soft key F2/F3.
Feed pump status This key has no function. The LED in the key shows the current
feed pump status:
– Continuous light: operation
– Slow flashing: post-running phase
– Quick flashing: motor-protection alarm
Solids pump status This key has no function. The LED in the key shows the current
solids pump status:
– Continuous light: operation
Separator status This key has no function. The LED in the key shows the current
separator status:
– Continuous light: Operation
– Slow flashing: start-up phase
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3.1.2 S ys te m ke ys
Arrow up/down/right/left With these keys one can navigate across the menus.
If a menu has input fields the arrow keys are used to navigate
from one field to another. After the last input field only, the next
menu is selected.
The arrow keys allow to navigate throughout the alarms within
the alarm memory or on the signal level.
ESC (cancel) With this key, field entries can be undone as long as they have
not been confirmed with ENTER.
If the ESC key is pressed within a menu, the previous menu or
the signal level is accessed.
From the signal level jumping back is not possible.
ENTER With this key

• one can confirm and finalize an entry
• one can acknowledge an alarm signal
• one passes from the signal level to the image level
EDIT This key allows to modify parameters or timer/counter setpoints.

The LED lights up when the edit mode is active.
3.1.3 S o ftke ys F1 – F4
Softkeys The softkeys have local functions. The actions which can be
triggered depend on the text seen in the display and are at-
tributed to the corresponding images.
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3.1.4 Parameter entries

Numeric values, e.g. passwords or setpoint updates, are entered by means of
the function keys.
Fig. 22
The corresponding figure (1) is seen right-hand above the function key.
Note:
If, by mistake, you failed to press the EDIT key correctly before entering param-
eters, the function of the respective function key will be active. Then you might
change the current operating mode of the separator.
However, by pressing the mistakenly actuated key again, you return to the origi-
nal mode.
An entry can be made in a menu when the cursor is flashing.

Changing a value:
• Press the EDIT key; the LED in the EDIT key lights up.
• Enter the new value or the password by means of the function keys.
• Finish your entry by pressing the ENTER key.
8555-9000-010/1207
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3.2 Switching-on the control unit
When you switch on the control unit

the adjacent initial display appears.
C7-613 Firmw.:V1.01
Bootl.:V1.01
> Startup <
Fig. 23
Required data is loaded from the Micro

Memory Card (MMC).
$ 002 transfer
> Downloading User-<

> Data <
Fig. 24
Then the unit runs up, showing the ad-

jacent display. The run-up time is ap-
Westfalia Separator prox. 3 minutes.
Mineraloil Systems • Press the ENTER key.
please press
>> ENTER <<
Fig. 25
An overview of all process data is dis-

played. From this overview the individ-
Step: OFF ual menus can be called up - refer to
Step: actual 0sec chapter 3.5 "Process data overview
Clean oil out 2.0bar (Home)".
Product Temp.: 93°C
Fig. 26
Note:
To avoid long run-up times the control unit should be under voltage even when
the separator is not used.
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3.3 Password protection

Certain entries and functions require prior entry of a password.
• Company-related basic settings
– Password Level 1
• Service
• Loading CPU data
When selecting these options you are requested to enter the required password.
Note:
You can obtain the passwords from Westfalia Separator.
When requested to enter the password

proceed as follows:
Password login: • Press the EDIT key.
Level : 0 – The LED in the EDIT key lights
Password: ...... up.
• Enter the password by means of the
function keys.
Fig. 27
• Press the ENTER key.

The password is accepted.
Password login: – A jump into password level 1 fol-
Level : 1 lows.
Password:....... • Press the ENTER key for the se-
cond time.
– A jump back into the previous
menu follows.
Fig. 28 • Actuate the arrow key, and the first
password-protected menu appears.
If there is no operation made for two minutes, the program returns to entry level
0 (Logout). For further processing the password has to be re-entered anew.
ATTENTION!
Then, however, the menu then called up is not protected. This means that even
unauthorized persons can carry out changes in this menu.
To protect the control unit against unauthorized access you should return within
the menu until you are in the openly accessible menu area.
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3.4 P ro g ra m s e q u e n c e diag ra m
Separator has been

switched on
*1
"Bypass operation" "Standby"

Separation process is interrupted by Separator is at operating speed, sepa-
previous ejection program ration process can be started with the
preselected operating mode and/or se-
lected separator.
*1, *2
“Separate status”
Separation is started. The individual
program steps are processed with the
times set, depending on the selected
operating mode.
*1 or through external signal

*2 or through fault
Fig. 29
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3.5 Process data overview (Home)

After having switched on the control
unit, acknowledged with the ENTER
Step: OFF
key, and after the run-up process, first
Step: actual 0sec the adjacent general overview ap-
Clean oil out 2.0bar pears.
Product Temp.: 93°C • The general overview can be ac-
cessed directly from any other menu
by means of the "Home" key.
Fig. 30
• From the main menu, more program
settings can be called up by means
of the “arrow down” key.
The individual program settings are
described on the following pages.
STATUS-WMS/SMS/PT2
PT2-actual: 4.7bar
PT2-Transm: HIGH
WMS-Sensor: Oil
Fig. 31
Sep-Type:OSD-6
Motor current: 0.0A
Speed: 0rpm
Mode:Single -01/36
Fig. 32
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Step:
Step: actual 0sec
Clean oil out 2.0bar
Product-Temp.: 93°C
Fig. 33
Firs t m e n u lin e
The current status within the program cycle is displayed.
S e c o n d m e n u lin e
Depending on the selected operating mode or separator, the current program
cycle (“step“) and the respective countdown are shown in the display.
The subsequent display texts can be shown as described in the following table
(also refer to separate documentation “Settings and faults”
Display Meaning
Off Separator is not switched on.
The separator is in its start-up phase; no process
Run-up
start is possible.
Circulation mode: The feed valve is in recircula-
Circulation mode tion mode. The separator is in its run-up or fault
mode, or the process has not been launched.
Waiting The separating process has been launched.
The bowl content is displaced without loss by
Displacement
opening the displacement water valve.
Waiting after displace- Displacement is followed by a 5 seconds’ waiting
ment period.
The solids space of the bowl is emptied by actu-
Total ejection
ating the operating-water valve.
The speed drop occurring during ejection is
Speed recovery
compensated.
The filling operation establishes the required wa-
Filling ter seal in the -96- version of VARIZONE and
UNITROL separators.
The filling cycle is followed by a 5 seconds’ wait-
Waiting after filling
ing period.
Feed - open The separating process is activated.
Sensor test (option) The individual sensors are tested.
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Th ird m e n u lin e
Display Meaning
The current pressure in the clean-oil discharge is
Clean oil discharge
displayed in bar.
Fo u rth m e n u lin e
Display Meaning
The current product-feed temperature is dis-
Product temperature
played in °C.
STATUS-WMS/SMS/PT2
PT2-actual: 4.7bar
PT2-Transm: HIGH
WMS-Sensor: OIL
Fig. 34
The current status for the WMS-SMS-PT2 sensor arrangement is displayed.
Display Meaning
The current pressure on the PT2 sensor is dis-
PT2-actual
played in bar.
The current pressure of the PT2 transmitter is displayed.
PT2-Transmitter: LOW This is displayed when no pressure prevails.
PT2-Transmitter: HIGH This is displayed when pressure prevails.
The current status of the WMS sensor is displayed.
This is displayed when the WMS sensor detects
WMS sensor: OIL
oil.
This is displayed when the WMS sensor detects
WMS sensor: WATER
water.
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• From the main menu, more program

settings can be called up by means
Sep-Type:OSD-6 the “arrow down” key.
Motor curr.: 0.0A
Speed: 0rpm
Mode:Single -01/36
Fig. 35
The currently selected separator type (OSD-X, OSE-X) is displayed. The sepa-
rator type is factory-set.
The current separator amperage is displayed. The amperage values differ in the
start-up, ejection, and operation cycles.
During the run-up phase of the separator the starting-time countdown is dis-
played in seconds. As soon as “0 sec“ appears the separator is ready for opera-
tion. Preselection is done on timer 10.
Display of the preselected separator operating mode. The operating mode of the
separator is factory-set. The following displays are possible:
tion (-91-).
Single or series (-01-) The separator is run with activated Water Con-
tent Monitoring System (-01-) (for more details
(Water Content Monitoring
refer to separator manual).
System)
tion (-01-).
Single or series (-01/36-) The separator is used for heavy fuel oil treat-
ment, with activated Water Content Monitoring
(WMS/SMS -HFO)
System (-01) and Solids Space Monitoring
System (-36-).
Single or series (-01/96-) The separator is used for lube oil treatment,
with activated Water Content Monitoring Sys-
(WMS/SMS -LO)
tem (-01) and Solids Space Monitoring System
(-96-).
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3.6 User settings
3.6.1 Calling up user settings
Fig. 36
“User settings” are called up by pressing “Home” key 1 twice.
Six user-setting overviews can be se-

lected by means of the “arrow-down”
F1-User-Time 1/6 key.Call up the desired menu by
F2-Time list 1 means of the corresponding function
F3-Time list 2 key.
F4-Counter
Fig. 37
F1-Analog ON 2/6
F2-Analog OFF
F3-Input list
F4-Output list
Fig. 38
F1-PID-Contr. 3/6
F2-Time recording
F3-Alarm counter
F4-Alarm memory
Fig. 39
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F1-Maintenance 4/6
F2-Volume
F3-Service Info
F4-Date/Time
Fig. 40
F1-Sep.Settings 5/6
F2-Contrast
F3-Language
F4-Speed monitoring
Fig. 41
F1-Free 6/6
F2-Free
F3-Free
F4-Free
Fig. 42
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3.6.2 User timings

Three groups of timer lists are available:
– User timings
– Timer list 1
– Timer list 2
Only in the “User timings“ menu can process-dependent time values be
changed without entering a password. The other two groups are modified by
service staff only.
ATTENTION!
Alter the timer settings only in a passive state. In active state mode, the previ-
ously set time first runs; the time change made does not become effective until
the next activation. All set times run backwards from the entered setpoint and
activate the programmed function when the time has elapsed.
Note:
A user timing is changed only when the product is exposed to varying degrees
of contamination or when the water pressure for displacement and filling water
varies (to be gauged by litre now and then). (The required information can be
found in the Installation Guidelines, chapter “Water quantity”).
All times are preset in the factory under consideration of the respective separa-
tor model and are adapted to the local conditions during commissioning.
• In the “User settings” overview, ac-

tuate the F1 key.
F1-User Time 1/6
F2-Time list 1
F3-Time list 2
F4-Counter
Fig. 43
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The individual values can be called up

successively by means of the “arrow-
User Timings down” key.
Changing the timer setting:
T20: Separation • Press the EDIT key.
P:7200sec A:1234sec The LED in the EDIT key lights up.
• Enter the new timer value by means
of the function keys.
Fig. 44 • Press the ENTER key.
The new value is accepted.
• Select the next timer value by
means of the arrow keys.
Actual
Timer Meaning Setpoint
value
T20 Separation 7200 s
T01 Displacement
Auto timer value calculated (option)
T02 Filling
Auto timer value calculated (option)
T10 Separator starting 600 s
T11 Alarm bridging 30 s
Note:
In the displayed timer, there is a letter before each value. These letters have the
following meanings:
• P: Preset
• A: Actual
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3.6.3 Timer lists 1 and 2

Precise information on the timers can be found in the separate description
“Settings and faults”.
• In the “User settings” overview actu-

ate the F2 or F3 key.
F1-User Time 1/6
F2-Time list 1
F3-Time list 2
F4-Counter
Fig. 45
The timers, except those mentioned in

chapter 3.6.2 “User timings”, are only
Time List 1 accessible by entering a password.
• The first timer menu is called up.
T00:Partial ejection • By means of the arrow keys the in-
P: 1.1sec A: 0sec. dividual timer menus can be subse-
quently browsed through and ad-
justed.
Fig. 46
Changing a timer setting :
• Press the EDIT key.
The LED in the EDIT key lights up.
• Enter the new value by means of the
function keys.
• Select the next counter value by
A fixed unit is allocated to each timer. If decimal places are specified, the time
can also be entered with this accuracy. The initial setpoints depend on the se-
lected separator type.
Note:
In the displayed timer, there is a letter before each value. These letters have the
following meanings:
• P: Preset
• A: Actual
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3.6.4 Counters
tuate the F4 key.
F1-User Time 1/6
F2-Time list 1
F3-Time list 2
F4-Counter
Fig. 47

C1: Flush ejection down” key.
Changing a counter setting:
P: 10 • Press the EDIT key.
A: 4 The LED in the EDIT key lights up.
function keys.
• Select the next counter value by
More information on the individual counters (C1 – C5) is found on the following
pages.
Flush ejection:
C1: Flush ejection

P: 10
A: 4
Fig. 49
Actual
Counter Meaning Setpoint P
value A
C1 Flush ejection 10
The number of total ejections to be performed until an automatic flush ejection is

to be triggered is entered in input field P. When operating without flush ejection,
set the counter to “0“.
Upon each total ejection performed, the actual value A is reduced by “one”.
When the “0” value is reached, the next total ejection will be followed by the de-
sired flush ejection.
Note:
The “Flush ejection“ counter generally responds only to total ejections per-
formed. Partial ejections are not taken into account. During flush ejections the
ejection monitoring system is out of action.
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Partial ejection:
C2: Partial ejection

P: 8
A: 2
Fig. 50
Actual
value A
C2 Partial ejection 8
When modifying the operating-water system, partial ejection programs can be

run on OSC and OSD separators as well, if desired.
The number of partial ejections to be performed until a double total ejection is to
be triggered is entered in input field P.
Upon each partial ejection performed, the actual value A is reduced by “one”.
When the “0” value is reached, the next partial ejection will be followed by the
desired double total ejection.
Note:
The partial ejection mode can be switched on/off after having entered the pass-
word as described in chapter 3.6.17 “Separator Settings” Factory setting: Off
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Filling in SMS mode:
C3: SMS Filling

P: 3
A: 2
Fig. 51
Actual
value A
C3 SMS Filling 3
For LO separation in 01/96 mode, a system check of the SMS function is carried
out by several filling-water injections. The number of filling-water injection inter-
vals is preselected on counter C3. The factory setting is 3 and should be used
for testing purposes only.
The number of filling-water ejections to be performed until the system pressure
detected by the SMS sensor and switching over from SMS to WMS operation is
established, is entered in input field A.
If no pressure is detected after the third filling-water injection, the ejection pro-
gram is triggered.
Sensor check (option):
C4: Sensor check

P: 5
A: 0
Fig. 52
Actual
value A
C4 This is where to define the number of 5
partial ejection intervals prior to an
automatic sensor check.
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Percent (by volume) water
C5:0.5-Vol-% Water
P: 3
A: 0
Fig. 53
Actual
value A
C5 In the separating program, with dis- 3
charge valve closed and T47 started,
the pressure in the bypass line is reg-
istered and reduced by one.
If, within the separating interval, the
“0“ value is reached, the alarm “Cau-
tion, water content > 0.5%” appears.
This alarm is coupled to T17. By
opening of feed valve T17 is activat-
ed, after expiry of T17 the alarm is
still active.
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3.6.5 Analog inputs (AI)

To adjust the analog inputs perform the following steps.
tuate the F1 key.
F1-Analog ON 2/6
F2-Analog OFF
F3-Input list
F4-Output list
Fig. 54

AI0: Motor current down” key.
1U3 6/7 10.5 A Changing the setting:
function keys.
• Select the next value by means of
the arrow keys.
Note:
More information on how to adjust the analog inputs is given on the following
pages.
Transformer:
AI0: Motor current

1U3 6/7 10.5 A
Transformer:
F1 Key >1:50<
Fig. 56
Input Function Terminal Value

AI 0.0 Motor current 1U3 6/7 10.5 A
By actuating the “F1” key several times, separator 1:10; 1:25; 1:50;
current transformer adjustment can be selected for 1:100
local motor starters.
Due to the different separator motor ratings, the transmission ratio of the current
transformer can be adjusted when using external motor starters, to ensure that
the display of the control unit indicates the correct motor current of the separa-
tor.
The desired transformer ratio can be selected by actuating the F1 key several
times.
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Ejection monitoring:
Ejection monitoring:
Offset: 2.0A
Bowl monitoring:
Offset: 2.0A
Fig. 57
Function Conditions
Ejection monitoring Just before an ejection the operating current is
read off, and the offset value is added. After
the ejection within the time setting of timer 27,
the operating current has to increase by this
value. The offset value is preset on this page.
While in separating mode, launch a total ejec-
tion by means of the "Start“ key and observe
the ejection current in the corresponding dis-
play. The ejection current is normally higher
than the rated current in the separating pro-
gram. Enter the difference between ejection
current and separating current (e.g. 2.0 A) as
offset value.
The ejection monitoring will be out of service if
0,0 A has been entered as offset value. This,
however, should be done in exceptional cases
only.
Bowl monitoring For bowl monitoring, the cyclical closing-water
impulse for the bowl hydraulics is checked, i.e.:
if the closing-water rate is too high, the bowl is
opened which causes the current to rise and is
monitored as follows:
- 3 seconds before closing-water impulse in-
jection, the actual operating current of the
separator is measured and stored.
- 3 seconds after closing-water injection, the
measuring operation is repeated, and the
value is compared with the previous operat-
ing-current value.
If the value differs from the adjusted bowl-
monitoring offset, a corresponding alarm is
signalled; the separating process is not inter-
rupted.
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Clean oil discharge:
AI1:Cl.oil discharge
Actual: 1.4bar
Min: 1.0 Max: 3.0
PT-Key -F1- 1:16
Fig. 58
Input Function Terminal Setting

AI 0.1 Clean oil discharge 1U2 12+/13- Min: 1.0 bar
By adjusting Min: 1.0 bar and Max: 3.0 bar, the Max: 3.0 bar
product-discharge signal can be called up if these
values are exceeded.
Actual:
In this line the current pressure in the product dis-
charge is displayed.
PT key: 1:6, 1:10, 1:16
The desired transformer ratio can be selected by ac-
tuating the F1 key several times.
PT2 Transmitter:
AI2:PT2 Transmitter
Actual: 1.7bar
Max: 5bar
PT-Key -F1- 1:10
Fig. 59

AI 0.2 PT2 Transmitter 1X2. Max: 6.0bar
61/63/SC
By adjusting Max: 5.0 bar, an alarm signal can be set
if the value is below or above this setting.
The alarm signal depends on the selected process.
Actual:
In this line the current value of the PT2 pressure
transmitter is displayed.
PT key: 1:6, 1:10, 1:16
The desired transformer ratio can be selected by ac-
tuating the F1 key several times.
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PID – temperature control (option):
AI3:PID-Controller
1X2.76/77 95°C
(Option)
Fig. 60

AI 0.3 PID controller 1X2. 76/77
The control-unit software is provided with a PID controller which, in combination

with optional hardware components, allows to control the product temperature.
The PID function is selected by actuating the PID key.
Adjustment of the control mode and/or adaptation of the controller to local condi-
tions is described in chapter 3.6.9 “PID Controller”.
Temperature monitoring (PT100 signal):
PT100 Product-Temp.
1X2.78/79 95°C
Min: 60°C Compens.
Max: 100°C 7°C
Fig. 61

PT100 Product temperature 1X2.78/79 95 °C (203 °F)
Min: 85 °C (185 °F)
Lowest limit value for
separating temperature
monitoring
Max: 105 °C (221 °F)
Highest limit value for
separating temperature
monitoring
The control unit has a direct PT100 input in two-line technology.

When the temperature is below the min. separating temperature, a START of
the separating program is impossible. Mind the corresponding note in the dis-
play.
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PID – temperature control (option):
Temp. registration
Peak: 120°C
Fig. 62
Display Meaning
Temperature regis- The highest temperature occurred is stored for evalua-
tration - peak tion of operating conditions.
3.6.6 Analog outputs (AO)

Process data, e.g. separator current and product temperature, can be forwarded
to a superordinate control system as 4-2 mA (for transmittal an amplifier with
galvanic insulation is provided).
To display the analog outputs perform the following steps.
tuate the F2 key.
F1-Analog ON 2/6
F2-Analog OFF
F3-Input list
F4-Output list
Fig. 63
• The individual values can be called

up successively by means of the “ar-
AO.1: Motor current row-down” key.
1X2.93/94/SC 1.9 A • More data can be found in the table
AO.2: Temperature of chapter 2.7 “Analog in-
1X2. 91/92/SC 3.0 A puts/outputs”.
Fig. 64
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3.6.7 Input list

For displaying the digital inputs (DI) perform the following steps.
tuate the F3 key.
F1-Analog ON 2/6
F2-Analog OFF
F3-Input list
F4-Output list
Fig. 65

DI0.0:Separator-ON row-down” key.
>0< 1X2.01/02 • More data can be found in the table
DI0.1:Sep.-Fail. of chapter 2.6 "Digital in-
>0< 1X2.03/04 puts/outputs”.
Fig. 66
Status Definition:
• 0 = Input signal 24 V DC not available
• 1 = Input signal 24 V DC available
3.6.8 Output list
For displaying the digital outputs (DO) perform the following steps.
tuate the F4 key.
F1-Analog ON 2/6
F2-Analog OFF
F3-Input list
F4-Output list
Fig. 67

DO0.0:Product valve row-down” key.
>0< 1X2.41/42 • More data can be found in the table
DO0.1:Water valve of chapter 2.6 "Digital in-
>0< 1X2.43/44 puts/outputs”.
Fig. 68
Status Definition:
• 0 = Input signal 24 V DC not available
• 1 = Input signal 24 V DC available
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3.6.9 PID controller

tuate the F1 key.
F1-PID-Controller3/6
F2-Time recording
F3-Alarm counter
F4-Alarm memory
Fig. 69

PID-Controller-Hand down” key.
Valve >Hand < Adjusting the PID controller:
F2-Key Contr. closed • Open or close the controller by ac-
F3-Key Contr. open tuating the F2 or F3 key.
the arrow keys.
Fig. 70 • Press the EDIT key.
function keys.
the arrow keys.
More information on how to adjust the PID controller is given on the following
pages.
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PID-Controller-Hand
Valve >Hand <
F2-Key Contr. closed
F3-Key Contr. open
Fig. 71
Display Meaning
PID controller – By actuating the PID controller” key, one of the two op-
Hand/Auto- erating modes of the PID controller can be selected:
• Hand: Opening of the valve is done via F3, closing
via F2.
• Auto: Automatic control of the valve by the PID con-
troller, using the preset parameters.
Valve –Hand/Auto- PID controller status display:
• Hand: PID controller in manual operation
• Auto: PID controller in automatic operation
F2 key The valve is closed while the PID controller is in manual
-Controller closed- operation.
F3 key The valve is closed while the PID controller is in auto-
-Controller open- matic operation.
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Setpoint 90°C
Actual 89°C
Kp (P part) 2.00
Fig. 72
Actual
Display Meaning Setpoint
value
Setpoint Entering the desired product
temperature
Actual value Displaying the current product
temperature
Kp (P part) Entering the control mode (pro- 2.00
portional value)
Note:
The control mode (Kp) is factory-set according to general practical experience
and need not be modified under normal conditions.
Adapting the measuring transducer:
AI 0.3PID-controller
1X2. 76/77 89°C
End value: 120°C
Fig. 73
Actual
value
AI 0.3 PID con- Current input value of the
troller 1X2. 76/77 PID controller
End value Setting the end value 120 °C
(248 °F)
In special cases, the 4-20-Ma signal is provided from outside, adaptation to the
local measuring transducer is required.
For this purpose the existing default value is simply overwritten with the desired
value.
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3.6.10 Time recording

tuate the F2 key.
F1-PIDcontroller 3/6
F2-Time recording
F3-Alarm counter
F4-Alarm memory
Fig. 74

TR1: WMS Time down” key.
Max in 24h 60min Adjusting the time settings:
Act.in 24h 0min • Select the next value by means of
Recent 24h 0min the arrow keys.
Fig. 75 • Enter the new value by means of the
function keys.
the arrow keys.
TR1: WMS Time

Max. in 24h 60min
Act.in 24h 0min
Recent 24h 0min
Fig. 76
Display Meaning
TR1 • During separation the period during which the WMS sensor
detects water is recorded. When TR3 has elapsed the time
recording is reset.
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TR2:Sludge pump time

Max. in 24h 60min
Act.in 24h 0min
Recent 24h 0min
Fig. 77
Display Meaning
TR2 • During separation the running time of the sludge pump is
recorded. When TR3 has elapsed the time recording is re-
set.
TR3: Time Reset

P: 24h
A: 5h
Fig. 78
Display Meaning
TR3 • When the preset “P” time has elapsed, all time records for
TR1 and TR2 are moved to “Last Xh”, and the “Act. in Xh“
value is reset.
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3.6.11 Alarm counters

For displaying the operation and alarm signal counters perform the following
steps.
tuate the F3 key.
F1-PID-controller3/6
F2-Time recording
F3-Alarm counter
F4-Alarm memory
Fig. 79

Sep. OP data row-down” key.
OP-hrs: 77h
Ejections 44
Starts 37
Fig. 80
Display Meaning
OP-hrs. Display of the number of operating hours of the sepa-
rator. This number is the basic reference for the re-
quired service operations (see separator manual).
Ejections The number of partial ejections performed is displayed
in this line.
Starts The number of complete start-up cycles performed is
displayed in this line.
WMS/ per. Number of WMS functions for each separation cycle.
On a UNITROL separator with WMS system activated,
(periodic)
the number of water removals for each preset separa-
tion cycle is recorded. In case of a manual separation
stoppage the displayed value is set to zero.
WMS/ tot. Number of WMS functions. On a UNITROL separator
with WMS system activated, the number of water re-
(total)
movals is continuously recorded. The displayed value
cannot be reset.
SMS/ per. Number of SMS functions for each separation cycle.
On a UNITROL separator with SMS system activated,
(periodic)
the number of bowl ejections for each preset separa-
tion cycle is recorded. In case of a manual separation
stoppage the displayed value is set to zero.
SMS/ tot. Number of SMS functions. On a UNITROL separator
with SMS system activated, the number of bowl ejec-
(total)
tions is continuously recorded. The displayed value
cannot be reset.
Water removal time The water valve opening time is continuously record-
total ed. The value cannot be reset.
8555-9000-010/1207
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Display Meaning
Water removal time The water valve opening time is recorded for each
periodic separation interval and is reset when the next ejection
is performed.
PTC-Alarm This alarm is recorded when a switch-off is triggered
by the PCT sensors incorporated in the windings of
the separator motor.
PAL-Alarm This alarm is recorded when the separating process is
cut off by the minimum pressure transmitter installed
in the product discharge line.
PAH-Alarm This alarm is recorded when the separating process is
cut off by the maximum pressure transmitter installed
in the product discharge line
FSH-Alarm This alarm is recorded when the separating process is
cut off by the maximum level switch installed in the
water discharge line (optional, no standard equip-
ment).
LSHH-Alarm LSHH – solids vessel. This alarm is recorded when
the separating process is cut off by the "high/high"
level limit switch installed in the solids vessel.
TSL-Alarm TSL – Product feed temperature. This alarm is record-
ed when the separating process is cut off by the PT
100 temperature sensor installed in the feed line.
TSH-Alarm TSH – Product feed temperature. This alarm is rec-
orded when the separating process is cut off by the PT
100 temperature sensor installed in the feed line.
ISL-Alarm Ejection monitoring. This alarm is recorded when the
ejection program is interrupted because the current
monitoring device responded.
SOLIDS PUMP- Response of the solids-pump motor protection switch
ALARM is recorded.
FEED PUMP Response of the feed-pump motor protection switch is
-ALARM recorded.
Black-outS The number of power failures occurred within the cur-
rent separation program is recorded.
Solids pump counter: The solids pump switch-on intervals of the last 24
recent 24 h hours is recorded.
Water removal alarm The number of continuous water removal cycles
greater than T23 is recorded.
Vibro-1 Alarm Vibration alarm, stage 1
This alarm is recorded when the separating process is
cut off by the (optionally available) vibration sensor in-
stalled on the separator.
Vibro-2 Alarm Vibration alarm, stage 2
This alarm is recorded when the separator is switched
off by the (optionally available) vibration sensor in-
stalled on the separator.
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3.6.12 Alarm memory

On the control unit, fault messages are registered in the alarm memory. Any
change in status (come/over/acknowledged) of a fault message gives a new en-
try in the alarm memory.
Max. 256 entries are memorized. As soon as the alarm memory cannot take in
more fault messages, the oldest entries are erased automatically.
Note:
Precise descriptions of the fault messages can be found in the separate descrip-
tion “Settings and faults”.

tuate the F4 key.
F1-PID controller3/6
F2-Time recording
F3-Alarm counter
F4-Alarm memory
Fig. 81
• The alarm memory display appears.

– The fault messages are registered
<Fault > K 001/015 in the alarm memory in chronolog-
#009 MOTOR PROTECT. ical order.
on 10.12.02 09:47:48 • Actuate the up/down arrow buttons.
This is to browse through the alarm
memory.
• Press the ESC key.
Fig. 82 This is to quit the alarm memory.
Legend of the display reading in the example:

Display Meaning
<Fault> A fault message is displayed.
K Status of fault message:
• K = fault message has come
• Q = fault message was acknowledged
• G = fault message is over
001/015 The fault message on display appears in position 1
(latest signal). The alarm memory contains 15 fault
messages. 001 to 256 are possible.
#009 MOTOR Fault no. and plain text of fault message.
PROTECT.
on 10.12.02 09:47:48 Date and time at the moment of change in status
(come/acknowledged/over) of the fault message.
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3.6.13 Maintenance
tuate the F1 key.
F1-Maintenance 4/6
F2-Volume
F3-Service Info
F4-Date Time
Fig. 83

Maintenance interval • Enter the new value by means of the
Setting function keys.
Set: 4000 h • Press the ENTER key.
Actual: 2145 h The new value is accepted.
Fig. 84
Under “Set”, a maintenance interval of 4000 h is factory-set as specified in the

separator manual. Under “Actual“, the number of separator operating hours is
displayed.
As soon the number of operating hours is reached, a collective alarm is trig-
gered, and a corresponding warning signal is displayed on the screen. The col-
lective alarm does not interrupt the separating program and has to be acknowl-
edged by means of the ENTER key.
Note:
For setting the maintenance interval refer to the Instruction Manual of the sepa-
rator installed.
8555-9000-010/1207
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3.6.14 Volume (option)

For entering data in “Volume info for SMS registration, displacement and filling”
and in “Sensor test”, proceed as follows:
tuate the F2 key.
F1-Maintenance 4/6
F2-Volume
F3-Service Info
F4-Date Time
Fig. 85
Volume info for SMS registration, displacement, and filling:
• Select the value by means of the ar-

row keys.
Volume until SMS • Press the EDIT key.
Liters The LED in the EDIT key lights up.
Volume displacement • Enter the new value by means of the
Liters function keys.
Fig. 86
Actual
value
Volume until SMS Depending on the size of the
separator, the value for “Volume
in litres until SMS registration” is
entered here according to the
“Bowl Volume” table (see sepa-
rate description “Settings and
trouble shooting”, chapter “Bowl
volume/speed settings”).
Volume Dis- Depending on the size of the
placement separator, the value for “Volume
in litres for displacement” is en-
tered here according to the
“Bowl Volume” table (see sepa-
rate manual “Parameters and
trouble shooting”, chapter “Bowl
volume/speed settings”).
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Filling water volume

Liters
---->>
Fig. 87
Actual
value
Filling-water vol- Depending on the size of the
ume separator, the value for “Volume
in litres for filling” is entered here
according to the “Bowl Volume”
table (see separate manual “Pa-
rameters and Trouble Shooting”,
chapter “Bowl volume/speed
settings”).
Sensor check:
• Select the value by means of the ar-

row keys.
Water impulses for • Press the EDIT key.
sensor check The LED in the EDIT key lights up.
T60: Start impulse • Enter the new value by means of the
P: sec A: sec function keys.
Fig. 88
Actual
Display Meaning Setpoint P
value A
Start impulse After a manual start or when 10.0 s
C4 “Sensor check” has ex-
pired, the filling and displace-
ment water valve is opened for
10 seconds.
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T61: Sensor interval

P: sec A: sec
T62: Sensor impulse
P: sec A: sec
Fig. 89
Actual
Display Meaning Setpoint P
value A
Sensor interval Filling (T60) is followed by a 3 3s
seconds’ pause via T61.
Sensor impulse When the T61 pause has end- 1s
ed, water is injected via T62
for one second, through the fill-
ing and displacement water
valve.
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3.6.15 Service information

For displaying the separator data and service addresses perform the following
steps:
tuate the F3 key.
F1-Maintenance 4/6
F2-Volume
F3-Service Info
F4-Date Time
Fig. 90

Separator ser. no. down” key.
-> 1234-567 <- The serial number and the commis-
Commissioning date sioning date can be adjusted:
-> 17.11.2002 <- • Select the value by means of the ar-
row keys.
Fig. 91 The LED in the EDIT key lights up.
function keys.
• Select the next value or browse the
menus by means of the arrow keys.
Display Meaning
Separator serial no. Entering the serial number of the separator to
be actuated
Commissioning date Entering the date of commissioning
Prog Displaying the current software number
Version Displaying the current software version
Control Unit Part-No. Part number of the control unit
Date Display of the current date
Time Display of the current time
Service Sep. Operating Displaying the number of operating hours
Hours
Operating time of the separator motor
Service addresses Here all the service addresses can be called
one by one.
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3.6.16 Date and time

For calling up date and time proceed as follows:
tuate the F4 key.
F1-Maintenance 4/6
F2-Volume
F3-Service Info
F4-Date/Time
Fig. 92
• Actuate the right/left arrow buttons.

Move the cursor to the desired val-
Change date/time ue.
26. 4. 3 16:13:19 • Press the EDIT key.
• Adjust the value by means of the
function keys.
Fig. 93 The new selection is accepted.
Note:
The selection is undone by pressing
the ESC key. The current setting is
maintained, and the system jumps
back to the previous menu.
Display Meaning
Date/Time Date and time displays are used to trace alarm sig-
nals accordingly. The date format is language-
dependent.
There is no “leading zero“ shown in the display. In
Fig. 93, the year “03“ is displayed as “3“.
The preset date is memorized for about 6 weeks
when the control unit is switched off.
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3.6.17 Separator settings

The preselected separator settings are default factory settings.
tuate the F1 key.
F1-Sep.Settings 5/6
F2-Contrast
F3-Language
F4-Speed monitoring
Fig. 94
Separator Selection
F1 Key
Model: OSD -6
Fig. 95
Function Conditions
Selecting the separator type • F1 = OSD-6, OSD-18,
OSD-35, OSD-60,
OSD-80
The control unit is factory-set to the separator type installed; consequently all
corresponding timer settings are loaded automatically. If, for service reasons, al-
location is re-made, the separator type can be selected by actuating the F1 key
several times.
Press the F1 key until the separator type shown in the display changes. To pre-
vent the type from being changed by mistake, selection is delayed by 3 se-
conds.
When exchanging the control unit, the separators of previous OSC, OSB, and
OSA series can be selected as well.
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Process selection
F1 Key
Op.mode: single -02
Fig. 96
Function Conditions
Selecting the separator operating mode • F1 = single -01,
single -02, single -01/36,
single -01/96, single -91
Actuate the F1 key until the desired operating mode of the separator type is dis-
played. An overview of the separator operating modes can be found in chapter
3.5, Process data overview (Home).
Solids selection
F1 key
MODE: LSHH
Fig. 97
Function Conditions
Selecting a level switch for the solids pump • LSHH, LSHH-LSH, LSHH-
when using Compact Units (CUs9: LSH-LSL,
no solids vessel
Press the F1 key until the desired level switches are shown in the display.
By means of the F1 key the CU function is selected, and the sludge pump is
started automatically when bowl ejection is triggered. In addition, the solids
pump is switched off via timer 40, according to solids tank volume and pump
throughput. The timers have to be adapted to local conditions, if required. Dur-
ing separation, pause-and-impulse cycles are performed which can be modified
by means of the T41 (pause) and T40 (operation) keys.
When selecting LSHH, only an alarm is produced via the level switch.
When selecting LSHH-LSH, the sludge pump is automatically started when bowl
ejection takes place. The pump is also turned on via LSH and stopped via T24.
When selecting LSHH-LSH-LSL, the sludge pump is switched on via LSH and
stopped via LSH when T24 has elapsed.
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Sep-off in idle run

F1 Key > OFF <
Sensor Check
F2-Key > OFF <
Fig. 98
Function Conditions
Switch-off of separator in idle run, as soon as a • F1 = ON/OFF
delay period has elapsed.
• Actuate the F1 key to activate automatic separator switch-off when running

idle.
When ON is displayed, the separator is turned off with a preceding bowl ejec-
tion, when no switch-over to separation (process) takes place at the end of the
T39 period..
Idle condition is established when an alarm is given along with feed valve
closing or after start-up. If this condition arises, the corresponding message is
shown in the display, and the alarm system is activated.
By actuating the F1 key again, automatic switch-off of the separator running at
idle is turned off.
Function Conditions
Sensor Check (Option) • F2 = ON/OFF
On UNITROL separators with activated WMS or SMS sensors, one can check
the WMS transmitter and the pressure switch in the bypass line for proper func-
tion by actuating the F2 key.
When starting the ejection program manually or at the end of the C06 counter
setting, the WMS and SMS sensors are checked for proper signal quality by in-
jecting water. Only when proper functioning is confirmed will the separating pro-
cess be released. In case of malfunction the corresponding alarms will be trig-
gered. The testing period for the WMS and SMS sensors can be preselected by
means of T3.
The sensor check is switched off by actuating the F2 key again.
Note:
When activating the sensor check, calculation of the automatic water injection
for displacement and filling is launched as well.
For this purpose, enter the bowl volumes (depending on the separator size) for
the operations "liters up to WMS registration", "liters for displacement" and "li-
ters for filling" from the separate manual "Parameters and troubleshooting" ac-
cording the specified table.
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PSL-Function check
F1 Key > OFF <
Partial ejection:
F2 Key >OFF<
Fig. 99
Function Conditions
PSL function monitoring • F1 = ON/OFF
• Press the F1 key to activate function monitoring of the pressure transmitter in

the product discharge.
With function monitoring switched on, the pressure transmitter in the ejection
program is checked for 0 status. Faulty permanent signal is thus prevented from
being triggered by a defect on the pressure transmitter.
If this fault arises, the corresponding message is shown in the display, and the
alarm system is activated.
Function monitoring is switched off by actuating the F1 key again.
Function Conditions
Partial ejection program selection • F2 = ON/OFF
• Press the F2 key to activate the partial ejection program.

When using OSD separators, partial ejections can be performed if desired, with
the corresponding operating water system. Time-dependent and SMS-
determined bowl ejections are preformed as partial ejections if the current value
on the partial-ejection counter C2 has not returned to zero.
Partial ejections that are launched by means of the "Process stop / start" but-
tons and by zero status of the C2 counter, are generally performed as total ejec-
tions.
The partial ejection program is switched off by actuating the F2 key again.
8555-9000-010/1207
Westfalia Separator
Bowl monitoring:
F2 Key >OFF<
Fig. 100
Function Conditions
Bowl monitoring • F2 = ON/OFF
• Press the F2 key to activate separator bowl monitoring.

For bowl monitoring, the cyclical closing-water impulse for the bowl hydraulics is
checked, i.e.: if the closing-water rate is too high, the bowl is opened which
causes the current to rise and/or the bowl speed to fall.
Bowl monitoring is controlled as follows:
– 3 seconds before the closing-water injection impulse, the actual operating
current of the separator is measured and memorized.
– 3 seconds after closing-water injection, the measuring operation is repeat-
ed, and the result is compared with the previously registered current and
speed values.
– If a deviation from the permissible offset value is observed, a corresponding
alarm is triggered.
– The separating process remains uninterrupted.
Bowl monitoring is switched off by actuating the F2 key again.
8555-9000-010/1207
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3.6.18 Contrast
For adjusting the display contrast proceed as follows:
tuate the F2 key.
F1-Sep.Settings 5/6
F2-Contrast
F3-Language
F4-Speed monitoring
Fig. 101
• Actuate the up/down arrow button.

Set the contrast to a value between
Display contrast: 0 and 15.
– 0 = lowest contrast
Contrast: 6 – 15 = highest contrast
The new selection is accepted.
Fig. 102 Note:

The selection is undone by pressing
maintained and the system jumps back
to the previous menu.
3.6.19 Language
For language selection proceed as follows:
tuate the F3 key.
F1-Sep. settings 5/6
F2-Contrast
F3-Language
F4-Speed monitoring
Fig. 103
Selecting a new language:

• Actuate the up/down arrow button.
Language selection: Browse through the languages.
Current: GER • Press the ENTER key.
New: ENG The new selection is accepted, the
program re-starts.
Fig. 104
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Westfalia Separator
Depending on the program version, five languages are available for selection.
Program version Languages Code

D10-0A1-V1.20* German GER
English ENG
French FRA
Italian ITA
Spanish ESP
* The program version can change due to technical progress.
Note:
$ 002 transfer The selection is undone by pressing
maintained and the system jumps back
>Parametrization < to the previous menu.
> running <
Fig. 105
For firmware reasons some system outputs are only available in the languages
of program version D10-0A1-V1.20*. If other languages are selected, the output
will be in English.
Note:
Following a language selection, the new language is transferred from the Micro
Memory Card (MMD) which takes approx. 3 minutes. During this period, no data
is shown on the display; the selection is accepted only after pressing the
ENTER key, and the program re-starts.
8555-9000-010/1207
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3.6.20 Speed monitoring (option)

Monitoring of the bowl speed for alarm signalling is pre-set via the min. and
max. values. For adjusting the speed monitoring parameters proceed as follows:
tuate the F4 key.
F1-Sep. settings 5/6
F2-Contrast
F3-Language
F4-Speed monitoring
Fig. 106
• By actuating the F1 key, separator

speed monitoring is activat-
F1-Speed ON/OFF>OFF< ed/deactivated.
Speed max:12000 rpm • When the min. – max. values are
Speed min:11000 rpm exceeded, the separator is switched
actual:11500 rpm off automatically.
Setting the speed monitoring parame-

Fig. 107 ters:
• Select the min. and/or max. value by
function keys.
8555-9000-010/1207
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Offset ejection mon.

270 rpm
Offset bowl monit.
100 rpm
Fig. 108
Function
Offset ejection monitoring
Just before an ejection the bowl speed is read, and the offset value is added.
After bowl ejection within the time setting of timer 27, the speed has to de-
crease by this value.
While in separating mode, launch a total ejection by means of the "Start“ key
and observe the ejection speed in the corresponding display. Normally the
ejection speed is lower than the separating speed. Enter the difference be-
tween ejection speed and separating speed as offset value.
Example:
(speed in separating mode: 10,000 rpm – ejection speed: 9,700 rpm) - 10 %
= offset speed: 270 rpm
The ejection monitoring is not operative if 0 rpm has been entered as offset
value. This, however, should be done in exceptional cases only.
Offset bowl monitoring
For bowl monitoring, the cyclical closing-water impulse for the bowl hydraulics
is checked, i.e.: if the closing-water rate is too high, the bowl is opened which
causes the speed to fall and is monitored as follows:
- 3 seconds before closing-water injection impulse, the actual speed of the
separator is measured and memorized.
- 3 seconds after closing-water injection, the measuring operation is repeat-
ed, and the value is compared with the previous speed value.
If the value differs by more than 100 rpm, a corresponding alarm is signalled;
the separating process is not interrupted.
Impules per rev.

2 Imp.
Fig. 109
Function
Impulses per revolution
Number of pulses energizing the bowl sensor per revolution of bowl.
• Set a value between 1 and 10.
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3.7 Changing the Micro Memory Card (MMC)

The control program and all setting/adjustment data are stored on the remova-
ble Micro Memory Card (MMC). If required, these data can be downloaded, e.g.
when the Micro Memory Card (MMC) is inserted in a new control unit.
The control unit cannot be used without the Micro Memory Card (MMC) or with
a defective card. In this case the message “CPU is in stop” will be displayed.
Fig. 110
1 "X7 MMC" port

2 Micro Memory Card (MMC)
Make sure that the power supply unit is switched off prior to changing the Micro
Memory Card (MMC).
When a new Micro Memory Card (MMC) has been inserted, the D10 unit is in
STOP mode when being switched on for the first time.
• Switch the voltage supply off and on again. The D10 will then be in RUN
mode.
The Micro Memory Card (MMC) must not be read out using commercially avail-
able card readers. The program may be destroyed.
Only the control unit purchased from Separator Mineraloil Systems GmbH can
read the program content on the MMC, and proper operation can be guaran-
teed.
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3.8 Memory reset
3.8.1 Setting the jumper
Only qualified staff or authorized specialists are allowed to open the control cab-
inet.
Normally the operating modes RUN, STOP, and MRES cannot be changed us-
ing the operating mode selector of the control cabinet. If, however, this is re-
quired for some reason, e.g. to reset the memory, a jumper has to be connected
between the terminals AT1 and AT2 for activating the authorization.
Whenever the operating mode selector switch is pressed, the status of the con-
trol unit is changed.
Fig. 111
1 Power supply connector X1

2 Jumper between AT1 and AT2
The RUN key has to be pressed for at least 500 ms to trigger the status change
and to make the key LED light up. The key LEDs do not indicate the operating
status of the control cabinet but the position of the operating-mode keys.
To continue using the unit the jumper has to be removed.
8555-9000-010/1207
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3.8.2 CPU reset

Under certain circumstances it might be necessary to reset the CPU of the con-
trol unit.
Resetting the CPU means that the CPU is reinitialised. The program currently
stored in the RAM and all data will be overwritten by the content of the Micro
Memory Card (MMC).
Fig. 112
• Select the operating mode “STOP” by pressing the DOWN key (2):
– the LED "S" lights up,,
– the LED "STOP" lights up,,
• Select the operating mode MRES by pressing the UP (1) and DOWN (2) keys
simultaneously.
– the LED "M" lights up,,
• Keep the keys pressed until the status LED “STOP” lights up a second time
and then remains on (after about 3 seconds).
• Then release the keys.
• You have to press the two keys again within 3 seconds.
• When the LED “STOP” flashes rapidly (at about 2 Hz), you can release the
keys.
When resetting of the CPU is finished the LED “STOP“ stops flashing and
changes into continuous light.
The CPU is now reset, and the program is in STOP mode.
Note:
The steps describe here are only necessary if the user wants to reset the control
unit himself. If the control unit requests to be reset, which is shown by slow
flashing of the “STOP” LED, it will be sufficient to press the UP (1) and DOWN
(2) keys simultaneously in order to start resetting.
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4 Maintenance and servicing
4.1 Accident prevention ............................................................................... 92

4.2 Removing faults ..................................................................................... 93
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4.1 Accident prevention

Be sure to observe the safety precautions in chapter 1 when carrying out
maintenance and repair work.
To be on the safe side, the most important safety precautions concerning
maintenance and repairs are repeated here.
Before carrying out maintenance and repair work:

• Switch off all electrical appliances via the main
switch,
• Lock the installation to prevent it from being ac-
cidentally switched on.
Fig. 113

Operating, maintaining or repairing the separator, the control system or the sep-
arator plant requires specialized knowledge!
CAUTION!

who
ing.
The operator of the separator, the control system or the separator plant
Westfalia Separator offers a an extensive range of training and advanced train-

ing courses. For more in-depth information, please check back with Westfalia
Separator or one of their authorised agencies.
8555-9000-010/1207
Westfalia Separator

Separator.
– safety risks,
ranty claims.
4.2 Removing faults

To remove faults, refer to the separate documentation “Parameters and Trouble
Shooting”.
8555-9000-010/1207
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Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note
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Westfalia Separator
5 Installation and connection
5.1 Installation of the control system ........................................................... 96

5.2 Connecting the control system .............................................................. 97
5.3 Centralised control via potential-free contacts....................................... 98
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5.1 Installation of the control system
Ge n e ral in s tallatio n in s tru c tio n s

• S p e c ia l a tte n tio n m u s t b e p a id to th e in s ta lla tio n g u id e lin e s o f We s tfa lia
S e p a ra to r.
• Mount the control system in the vicinity of the separator either on a wall or a
frame.
If you mount the control system on a wall, you must ensure a wall clearance
of approximately 20 mm.
• Seal the fastening holes on the rear of the control cabinet by putting seals un-
derneath.
• Take into consideration the following criteria when selecting the installation
site:
– Direct sunlight on the display should be avoided if possible to ensure that
the display can be read.
– Heating up of the device by external heat sources should be largely exclud-
ed.
– The control system should not be mounted in moist environments or wet
areas (see also section “Technical data”).
In the c a s e o f s h ip b o ard o p e ra tio n :

• Fasten the control system in a way to avoid vibrations.
• Do not fit the control system in the vicinity of hot pipes.
• Arrange the air discharge from the ventilator and filter so that adequate venti-
lation is assured.
Hu m id ity / d ew
If there is a risk that the control system is exposed to dew, the supply voltage
should always be switched on to keep the temperature inside the control cabinet
as constant as possible.
If power is supplied via the motor starter, the main switch should remain on.
8555-9000-010/1207
Westfalia Separator

tor!

ponents:
standstill.
5.2 Connecting the control system

• S p e c ia l a tte n tio n m u s t b e p a id to th e in s ta lla tio n g u id e lin e s o f We s tfa lia
S e p a ra to r.
• The inputs and outputs are allocated to the corresponding terminal blocks on
the subplate as specified in the terminal diagrams.
Op e ratin g vo lta g e s
• Connect the control system only to voltages that are specified on the name-
plate inside the control cabinet.
The standard rating for the control voltage for solenoid valves for operating
water and control air is 24 VDC.
Da n g e r th ro u g h e xte rn a l vo lta g e !
Th e vo lta g e -fre e c o n ta c ts o f th e in te rfa c e re la y c a rry e xte rn a l vo lta g e s if
th e y a re , fo r e xa m p le , u s e d a s in te rlo c ks in p u m p c o n tro ls .
The output modules are provided with short-circuit proof transistor outputs.
In s tallatio n re g u latio n s :
• Lay the signal lines separate from lines with high voltages (e.g. power cables,
motor leads etc.).
• Firmly tighten the cable glands for leading in the cables.
8555-9000-010/1207
Westfalia Separator
5.3 Centralised control via potential-free contacts

The integration of local separator control units into the customer's central control
systems requires the communication signals to be discussed when placing the
order.
The control unit can be linked to a cen-

tralised control system via a hardware
signal.
A potential-free contact indicating the

collective alarm can be used for cus-
tomer-side evaluation.
Fig. 116 Wiring diagram (example)
8555-9000-010/1207
Westfalia Separator
8555-9000-010/1207
Westfalia Separator
Mineraloil Systems GmbH
Take the Best - Separate the Rest
A company of GEA Group
Westfalia Separator Mineraloil Systems GmbH ● Werner -Habig-Straße 1 ● D-59302 Oelde (Germany)
Phone.: + +49 (0) 25 22/77-23 94 ●
http://www.westfalia-separator.com/● mailto:info@gea-westfalia.de
Instruction manual
Designation: Mineral oil centrifuge with self-cleaning bowl
Type: OSE 10-91-067
No. 2065-9001-202 | Edition 0613

2 2065-9001-202 / 0613
ORIGINAL INSTRUCTION MANUAL

The authors are always grateful for comments and sugges-

tions for improving the documentation. They can be ad-
dressed to:

Werner-Habig-Straße 1, 59302 Oelde, Germany
Phone: +49 2522 77-0, Fax: +49 2522 77-2488
www.gea.com

2065-9001-202 / 0613 3

Type S/N:
Year of manufacture
Max. permissible rated bowl speed in rpm
3
Max. permissible density of product in kg/dm
3
Heavy liquid kg/dm
3 Solids kg/dm
3
min/max throughput m /h
min/max temp. of product in °C
min/max housing pressure range in bar
This nameplate must be filled in by the operator.

Please transfer the data from the centrifuge nameplate.

4 2065-9001-202 / 0613
For your safety

symbol -

This avoids damage to the separator and other equipment.
mation which help to better understand the separator or plant compo-
nents and the processes.

tionally to the operation of the separator. The plant operator must en-
sure compliance with these regulations.
• When operating electrical apparatus, certain parts carry danger-

ous voltage.
Before working in electrical components, take adequate preventive
measures according to the national provisions (in Germany in accord-
ance with the rules and regulations of the VDE (Verein Deutscher El-
ektrotechnik / Association of German Electrical Engineering) or of the
Non-compliance with the protective measures can result in serious
damage to persons or property.
Any work on electrical components may only be carried out by an au-
thorized electrician.
• Only qualified or authorized specialized staff may operate, main-

tain and repair the separator.
Corresponding training courses take place in the manufacturer’s plant
or are held on site by the manufacturer.

Follow only the instructions given in this manual.
in this manual may not be carried out.
• Operate the separator only in accordance with agreed process

and operating parameters

2065-9001-202 / 0613 5
• Maintain the separator

as specified in this manual.
• Carry out safety checks on the separator,

as described in chapter "Safety precautions" in this manual
• Liability for the function of the machine passes to the owner.

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

6 2065-9001-202 / 0613
1.1 Correct usage ........................................................................................ 10

1.3 Safety markings ..................................................................................... 12
1.4 Basic operating principles ...................................................................... 17
1.5 Operations on the separator .................................................................. 18
1.5.3 Assembly ............................................................................................... 19
1.5.5 Before start-up ....................................................................................... 23
1.5.6 Start-up .................................................................................................. 25
1.5.7 Shut-down and “Emergency-Off" ........................................................... 27
1.5.8 Voltage cutoff during operation .............................................................. 28
1.6 Corrosion ............................................................................................... 33
1.7 Erosion ................................................................................................... 34
1.8 The health hazards involved when handling heavy oils and lube oils ... 36
1.8.1 Code of practice and personal protective measures ............................. 36
2 Machine description 37
2.1 Dimensioned drawing of the separator .................................................. 38

2.2 General .................................................................................................. 38
2.3 Separator ............................................................................................... 38
2.4 Main components of the separator ........................................................ 41
2.4.1 Centripetal pump ................................................................................... 42
2.4.2 Bowl ....................................................................................................... 43
2.4.3 Bowl hydraulics ...................................................................................... 44
2.4.4 Drive ....................................................................................................... 47
2.5 Regulating ring ....................................................................................... 50
2.5.1 Determination by table ........................................................................... 50
2.5.2 Determination by experiment ................................................................. 51
2.6 Supervisory equipment .......................................................................... 52
2.6.1 Pressure transmitter .............................................................................. 52
2.6.2 Vibration monitoring (Option) ................................................................. 53
2.6.3 Speed monitoring ................................................................................... 54
2.7 Product feed line and product discharge line ........................................ 55
2.7.1 Throughput monitoring (product feed line A) ......................................... 55
2.7.2 Throughput determination (product feed line A) –
only for control D10 ................................................................................ 56
2.7.3 Pressure monitoring (product discharge line B) .................................... 57
2.8 Standard tools ........................................................................................ 58
2.9 Special tools .......................................................................................... 60
2.9.1 Using load-carrying equipment safely ................................................... 62
2.9.2 Safely using eyebolts and ring nuts as load-carrying equipment. ......... 62
2.10 Technical data ....................................................................................... 64
2.11 Screw torques ........................................................................................ 66
2.11.1 Screw torques in Newton meters (Nm).................................................. 66
2.11.2 Screw tightening torques in inch-pound (inlb) ....................................... 67

2065-9001-202 / 0613 7
3 Operation 69
3.1 Technical information ............................................................................. 70

3.1.1 Separation.............................................................................................. 70
3.1.2 General information on bowl ejection .................................................... 70
3.2 Before start-up ....................................................................................... 72
3.2.1 Before the first start-up – after maintenance and repair ........................ 72
3.2.2 Before every start-up ............................................................................. 74
3.3 Starting the separator ............................................................................ 75
3.4 Monitoring of operation .......................................................................... 77
3.5 Setting the separation time .................................................................... 78
3.5.1 Mathematical calculation ....................................................................... 78
3.6 Bowl ejection .......................................................................................... 79
3.7 Shutting down the separator .................................................................. 80
3.7.1 Shut-down “Emergency-Off" .................................................................. 82
3.8 Trouble shooting .................................................................................... 84
3.8.1 Trouble shooting .................................................................................... 84
3.8.2 Bowl faults.............................................................................................. 86
4 Installation - Maintenance - Repair 93
4.1 Installation of the separator ................................................................... 94

4.1.3 Motor ...................................................................................................... 97
4.1.4 Direction of rotation of the bowl ........................................................... 100
4.1.5 Speed and starting time of the bowl .................................................... 101
4.2 Fitting orifice plates, flow indicator, pressure transmitter .................... 103
4.2.1 Installing the orifice plates ................................................................... 104
4.3 Maintenance and lubrication ................................................................ 105
4.3.1 Maintenance schedule ......................................................................... 105
4.3.2 Hoses and hose pipes ......................................................................... 113
4.3.3 Lubrication ........................................................................................... 114
4.3.4 Lubrication Chart ................................................................................. 116
4.3.5 Table of lubricating oils ........................................................................ 118
4.3.6 Comments on table of lubricating oils for separators from
GEA Westfalia Separator Group ......................................................... 119
4.4 Bowl ..................................................................................................... 120
4.4.1 Dismantling the bowl ............................................................................ 122
4.4.2 Cleaning the bowl ................................................................................ 138
4.4.3 Cleaning the frame .............................................................................. 139
4.4.4 Cleaning the strainer and the operating water feeding system ........... 139
4.4.5 Cleaning the motor .............................................................................. 140
4.4.6 Important instructions for assembling the bowl ................................... 141
4.4.7 Assembling the bowl ............................................................................ 143
4.4.8 Replacing the polyamide gasket (bowl top) ........................................ 157
4.4.9 Replacing the polyamide gasket (annular piston)................................ 159
4.4.10 Reworking the sliding piston ................................................................ 166
4.5 Closing the hood .................................................................................. 167
4.6 Drive ..................................................................................................... 170
4.6.1 Important instructions for fitting and removing the drive ...................... 172
4.6.2 Removing the drive belt and spindle assembly ................................... 174
4.6.3 Dismantling the spindle assembly ....................................................... 178
4.6.4 Dismantling the centrifugal clutch ........................................................ 180
4.6.5 Fitting the spindle assembly ................................................................ 184

8 2065-9001-202 / 0613
4.6.6 Fitting the centrifugal clutch ................................................................. 187

4.6.7 Fitting the motor ................................................................................... 193
4.7 Height adjustment ................................................................................ 198
4.7.1 Bowl height .......................................................................................... 198
4.7.2 Centripetal pump clearance ................................................................. 199
4.8 Final checks after assembling the separator ....................................... 201
4.9 Before a long-term shut-down of the separator ................................... 201
4.9.1 Preserving the separator ..................................................................... 201
4.9.2 Preserving the motor ........................................................................... 202
4.10 Storage ................................................................................................ 203
4.10.1 After delivery ........................................................................................ 203
4.10.2 Separator ............................................................................................. 203
4.10.3 Control system ..................................................................................... 204
4.11 Before restarting .................................................................................. 204
4.12 Disposal ............................................................................................... 205
4.12.1 Gear and lubricating oils ...................................................................... 205
4.12.2 Cleaning fluids ..................................................................................... 206
4.12.3 Separator ............................................................................................. 206
5 Spare parts 207
5.1 Spare part requirements ...................................................................... 208

5.2 Guide to ordering spare parts .............................................................. 208

2065-9001-202 / 0613 9
1.1 Correct usage ........................................................................................ 10

1.3 Safety markings ..................................................................................... 12
1.4 Basic operating principles ...................................................................... 17
1.5 Operations on the separator .................................................................. 18
1.5.3 Assembly ............................................................................................... 19
1.5.5 Before start-up ....................................................................................... 23
1.5.6 Start-up .................................................................................................. 25
1.5.7 Shut-down and “Emergency-Off" ........................................................... 27
1.5.8 Voltage cutoff during operation .............................................................. 28
1.6 Corrosion ............................................................................................... 33
1.7 Erosion ................................................................................................... 34
1.8 The health hazards involved when handling heavy oils and lube oils ... 36
1.8.1 Code of practice and personal protective measures ............................. 36

10 2065-9001-202 / 0613
1.1 Correct usage

Centrifugal separators – called separators in short – are used
• for the separation of liquid mixtures which consist of two liquids, with simulta-
neous removal of the solids contained in the liquids.
• for removing (clarifying) solids from a liquid.
The separator is designed

• for a very high bowl speed.
The admissible bowl speed depends on the chemical and physical properties
of the product:
– Temperature
– Density of the fluid and solid components.
• for products which contain no corrosive and erosive components.
The aggressiveness of the product influences the careful selection of the bowl
material.
Only products conforming to the specifications on the nameplate may be pro-
cessed.
• in accordance with the method of application of the separator agreed with
GEA Westfalia Separator. Refer to the data sheet and contractually agree-
ments.
• in accordance with the admissible utilities (cleaning agents, lubricants, operat-
ing liquids etc.) specified in the documentation or on the data sheet.
Intended use involves

• paying attention to the safety precautions, the instruction manual of the sepa-
rator and the safety markings on the separator.
• adhering to the data on the nameplate, e.g. maximum admissible bowl speed.
Further information on the intended use of the separator such as
– agreed areas,
– density of the product
– throughput capacities
– temperatures
– pressures etc.
is given in the documentation or the data sheet furnished with the documenta-
tion.
The contractually agreed conditions agreed with GEA Westfalia Separator on
the intended use of the separator must be passed on to the operating personnel
by the plant operator.
Any operating mode deviating from this is not intended use and can result
in severe damage to property and persons!

2065-9001-202 / 0613 11

Any use that deviates from the intended use is considered to be non-
compliant.
The separator may not be operated by:

• Persons who have not read and understood these basic safety precautions.
• Persons who have not read and understood the instruction manual of the
separator.
• Persons who have not been briefed on proper and correct operation.
• Persons who have not been adequately trained.
• Persons who have not reached the minimum age of 18 years.
The separator may not be operated

• when the product fed does not conform to the specifications on the name-
plate.
– Product with excessively high density
– Solids with excessively high density
– Product with excessively high temperature
• when the max. admissible bowl speed has been exceeded through electrical
or electronic manipulation of the drive.
• in an incomplete state of assembly, e.g.
– required supervisory equipment is not activated or has been switched off.
– the required safety and/or protective covers have not been installed.
• by persons who are not adequately trained.
• when the separator is operated with spare parts which do not come from GEA
Westfalia Separator.
Non-compliance with intended use can result in severe damage to proper-

ty and persons!

12 2065-9001-202 / 0613
1.3 Safety markings

The safety markings (adhesive and metal plates) are attached to all separators
on the hood and frame of the respective separator in such a way that they are
clearly visible.
All safety markings on the separator, control system and plant components must
always be in perfect condition.
Fig. 1 Example of markings on a separator
1 Pictograms (safety stickers)

2 Oil quality
3 Plates
4 Nameplate
5 Maker's nameplate
The texts and part numbers of the safety markings change depending on the
languages required by the customer.

2065-9001-202 / 0613 13

The following safety markings must be attached to the separator as adhesive
labels.
Fig. 2
Refer to the machine documen-

tation!
taining and repairing the machine
must have read and understood the
documentation.
plete kept near to the machine and
be readily accessible to the opera-
tors. It must be available to the op-
erators at all times!
Fig. 3

14 2065-9001-202 / 0613

tor!

ponents:
standstill.
Danger to life and limb through

rotating machine parts!
• Do not loosen any part and do not
carry out maintenance or repair
work on the separator before the
separator is at a standstill.
Methods of how to check standstill
are described in the machine docu-
mentation.
Fig. 5
Warning of unusual noises or

vibrations!
When unusual noises or vibrations
occur on the separator:
off”.
centrifuge has come to a standstill.
Fig. 6

2065-9001-202 / 0613 15
Frequency converter operation!

• When setting the frequency convert-
er, do not exceed the admissible
bowl speed (see nameplate)
Note:
This adhesive plate is only used for
frequency converter operation.
Fig. 7
Warning of extreme surface

temperatures!
The surfaces of the separator and

plant components can be hot!
Note:
This adhesive plate is only used for hot
operation.
Fig. 8
Danger due to electrical voltage!

Before working on electrical separa-

tor/plant components:
Fig. 9
CAUTION:
The parts marked in this way can carry voltage even when the main
switch is off!
• Lock the separator/plant to prevent it from being accidentally switched on.
Deutscher Elektriker / Association of German Electrical Engineers) or of the
specialists).

16 2065-9001-202 / 0613
Pictograms with warning text

Pictograms can be meaningfully supplemented as illustrated in the two following
examples:
– With warning text (Voltage is also present . .),
– with signal word (ATTENTION!) and warning text.
Bei ausgeschaltetem Sous tension même

Danger through external voltage!
Hauptschalter en position d’arrêt de
unter Spannung! l’interrupteur principal !
Voltage also present Con el interruptor

Voltage also present when main switch
when main
switch is turned off!
principal desconectado se
encuentra bajo tensión! is turned off!
CAUTION:
switch is off!
Fig. 10 Example 1
ACHTUNG! Danger through external voltage!

Auch bei ausgeschaltetem
Hauptschalter können
orangefarbige Leitungen
unter Spannung stehen.
ATTENTION!
ATTENTION!
Also in case of switched off main isola-
Also in case of switched off tor orange coloured cores can be un-
main isolator orange coloured cores
can be under voltage. der voltage.
ATTENTION!
Lorsque le commutateur principal
est éteint les files orange
peuvent être sous tension. CAUTION:
switch is off!
Fig. 11 Example 2
No te :
Orange coloured leads are fitted as standard at GEA Westfalia Separator.
Different colour leads can be fitted if requested by the customer!

2065-9001-202 / 0613 17

earth.
Fig. 12
1.4 Basic operating principles

Separators are used for the separation of liquid mixtures or for the separation of
solids out of liquids or liquid mixtures.
High centrifugal forces are produced in

the rotating bowl.
Fig. 13
Under the influence of the centrifugal forces, separation of the liquid mixture
and/or ejection of the solids particles takes place most rapidly.
The specifically heavier components are displaced to the bowl periphery,
whereas the specifically lighter components are displaced towards the centre of
the bowl.
The high centrifugal force is produced by very high bowl speeds. On the one
hand, high bowl speeds signify high efficiency, while on the other hand, they
signify high material stressing of the separator.

18 2065-9001-202 / 0613
1.5 Operations on the separator
The separator works reliably, provided

that it is operated and maintained in
accordance with our operating instruc-
tions.
Fig. 14

• Assembly
• Electrical installation
• Before start-up
• Start-up
• Shut-down
• Maintenance and repair

Operating, maintaining or repairing the separator or the separator plant requires
specialized knowledge.
CAUTION!
GEA Westfalia Separator accepts no liability for damage caused by un-

qualified or unauthorized personnel!
who
ing.
The operator of the separator or separator plant


2065-9001-202 / 0613 19
GEA Westfalia Separator offers an extensive range of training and advanced

training courses. You can obtain further information from GEA Westfalia Sepa-
rator or from one of the authorized representatives.
• Use only genuine spare parts from GEA

Westfalia Separator Group. The genuine
spare parts are listed in the spare parts cata-
log.
– Safety risks
– Reduced durability of these parts
– Reduced availability of the separator
Fig. 15
– Increased service requirement
If a safety risk occurs when using non-genuine
for the responsible persons. In such cases, GEA
Westfalia Separator Group accepts no liability or
warranty claims.
1.5.3 Assembly
• If the plant has several centrifuges,

be careful not to interchange parts of
different bowls since each bowl has
been balanced individually.
The bowl parts are marked with the
serial-number of the machine or with
the last three digits of the serial-
number.
Fig. 16

parts.
Fig. 17

20 2065-9001-202 / 0613
CAUTION:
• Some bowl parts may be pre-
assembled and balanced only by
specialists from GEA Westfalia
Separator or in workshops au-
thorized by GEA Westfalia Sepa-
rator.
Unqualified balancing can lead to
dangerous operating states (vi-
brations) and destruction of the
separator with danger to life.
Fig. 18
• To avoid unbalance, when replacing

some bowl parts like
– Lock ring
– Bowl top
– Distributor
– Bowl bottom
– Water chamber bottom
GEA Westfalia Separator must be
consulted.
These parts
– are marked with a footnote in the
separator manual (see section
“Bowl”).
Fig. 19 – are marked in the column “ETS” of
the parts list with a 3 or 4.
• Some bowl parts are arranged in

fixed positions relative to one anoth-
er.
• Locking devices and alignment
marks must be in perfect condition.
The bowl must otherwise not be op-
erated.
Fig. 20
• When transporting and assembling

machine parts, avoid crushing and
shear strain.
Fig. 21

2065-9001-202 / 0613 21
• When assembling the bowl, be sure

to strictly adhere to the assembly in-
structions in order to avoid undue
imbalance.
• Before starting the bowl, be sure to
fit all parts.
Fig. 22
CAUTION:
A loose lock ring can endanger life!
• Tighten the bowl lock ring securely:

the "O" marks on the bowl bottom or
bowl top and on the lock ring must
be aligned.
• Pay attention to the position of the
marks!
Fig. 23
CAUTION:
A loose spindle screw can endanger
life!
• Tighten the spindle screw with the

separator-specific torque (left-hand
thread).
Fig. 24
CAUTION:
A loose centripetal pump lock ring
or cover can endanger life!
• Tighten the centripetal pump cham-

ber lock ring or cover securely
(left-hand thread).
Fig. 25

22 2065-9001-202 / 0613
• Carefully fasten hood 1, feed and

discharge housing 2 and centripetal
pump 3.
Fig. 26
• Ensure that the machine is com-

pletely assembled and properly in-
stalled.
Fig. 27

cian!
installation guidelines of GEA West-
falia Separator.
Fig. 28

– Low-voltage guideline 2006/95/EC,
– Electromagnetic compatibility 2004/108/EC,

2065-9001-202 / 0613 23
1.5.5 Before start-up
• Check that the bowl lock ring has

been firmly tightened.
• The "O" marks on bowl bottom or
bowl top and on the lock ring must
be aligned.
Fig. 29
• The bowl must rotate in clockwise

direction (see arrow on frame or sol-
ids collector).
Fig. 30
• The separator may only be operated

with protection devices conforming
to EN 294.
• Equip solid and liquid discharges
accordingly where appropriate.
Fig. 31

24 2065-9001-202 / 0613
• Check that the lubrication and cool-

ing systems are serviceable.
Fig. 32
• Check whether the supervisory

equipment is operational and the
correct limit values are adjusted.
• When hoods, concentrate collectors
and vessels are pressurized, e.g. by
– inert gas blanketing,
– cooling,
– steam sterilization etc.
the pressures stated on the boiler
plate must not be exceeded.
Fig. 33
• Check that the product lines are set

to operation.
• Regularly check hoses for signs of
ageing.
• Check sight glasses for mechanical
damage.
parts.
Fig. 34

2065-9001-202 / 0613 25
1.5.6 Start-up
• Refer to chapter “operation”.

• Note nameplate. The values for
– bowl speed,
– density of the heavy liquid,
– density of the solids (centrifugally
dry)
are maximum values and must not
be exceeded.
Fig. 35
• Wear ear protection.
Fig. 36

operation:
manipulate the frequency converter
to exceed the permissible bowl
speed (see nameplate).
• The separator may only be operated
with an independent device for
speed limiting.
Fig. 37

26 2065-9001-202 / 0613
• Do not feed product which is catego-

rised as explosive.
• The separator must not be used in
areas where explosion protection is
required.
Fig. 38
• When processing products harmful

to persons, observe the pertinent
safety regulations.
• Refer to the safety data sheet of the
product.
• Use protective gear, e.g.
– Protective clothing
– Eye protection
– Protective mask
Fig. 39

off”.
separator has come to a standstill.
Fig. 40
Only in case of hot operation:

• Product-contacting parts such as
– pipes and hoses,
– hood,
– solids catcher
o
reach temperatures over 80 C .
o
(176 F).
Fig. 41

2065-9001-202 / 0613 27
• The bowl is not allowed to run with-

out liquid supply for more than 15 –
30 minutes, as otherwise it would
result in overheating of the bowl ma-
terial.
Fig. 42
1.5.7 Shut-down and “Emergency-Off"
• For shut-down of the separator refer

to the chapter "Operation" of this
manual and follow the start-up and
shut-down instructions.
Fig. 43

28 2065-9001-202 / 0613
1.5.8 Voltage cutoff during operation

When the voltage is cut off for longer than one second during operation, the
control system switches off automatically and the separating process is aborted.
Important:
– The bowl is not emptied. Product and solids remain in the bowl.
– The separator motor and product feed pump will be switched off.
– The control system switches itself back on automatically when the power
returns.
After the power returns

• Switch on the separator motor and product feed pump.
A closing water pulse after run-up of the separator triggers a total ejection au-
tomatically.

off”.
Fig. 44

2065-9001-202 / 0613 29
1.5.9 Maintenance and repair

Unfavourable operating conditions may require shorter maintenance intervals.
The factors listed below are unfavourable because they either attack the sepa-
rator material directly or impair the lubrication/cooling system:
• Aggressive product (chemical or physical)
• High product temperature
• Product with grease-decaying properties
• Environment: Temperature, dust, vapours
Particularly high-stressed separator

parts like
– Bowl lock ring,
– bowl bottom,
– bowl top and
– other bowl parts with a large outer
diameter
must be checked regularly to assure
safe and efficient operation.
Fig. 45
Timely maintenance of the separator and replacement of worn or damaged ma-

chine parts is essential for safe operation of the machine.
Use only genuine spare parts from Westfalia Separator. Otherwise, safety
risks may arise (see section 1.5.2).
Carry out the required cleaning thoroughly.

One-sided solid deposits in the bowl cause severe unbalance!
Maintenance and repair work may only be carried out to the extent described in
this instruction manual.
Maintenance and repair work not described in this manual may only be
carried out by the manufacturer or by "repair shops" authorized by the
manufacturer.
We, therefore, recommend in your own interest to have your separator inspect-
ed by our service engineers at regular intervals. These checks help to maintain
the operating safety and avoid unexpected downtime.

30 2065-9001-202 / 0613

ponents:
standstill.
Fig. 46
• Do not loosen any part and do not

carry out maintenance or repair
work on the separator before the
separator is at a standstill.
The standstill check is described in
the section “bowl”.
Fig. 47
• Do not climb onto or stand on the

machine or parts of the machine.
• Make provision for and use a sturdy
working platform.
Fig. 48
• Place dismantled machine parts on

a suitable base, e.g. rubber mat.
• Secure machine parts from rolling
away and overturning using suitable
aids!
Fig. 49

2065-9001-202 / 0613 31
• Do not heat bowl parts with the

naked flame.
• Bowl parts must never be welded.
This also applies for hood and
solids catcher parts of steam-
sterilizable separators.
• Even during cleaning the bowl parts
the temperature must not exceed
100 °C (212 °F).
Fig. 50
• Load-carrying equipment such as

– lifting devices for bowl or distribu-
tor,
– chains etc.
may only be used for their intended
purpose, i.e. the work routines as
described in this instruction manual.
• Do not use damaged or incomplete
load carrying equipment.
Fig. 51
• All load suspension devices have to be checked for completeness and for
possible damage at least once a year.
• In addition, when using load suspension devices and hoists, the applicable
legislation and safety rules have to be strictly observed.
CAUTION: Danger to life when transporting heavy parts!

• Do NOT step under hanging load.
• Special tools (e.g. compressing, assembly devices, pin spanners) may only
be used for their intended purpose, i.e. the work routines as described in this
instruction manual.
• Before using the standard and special tools supplied, check them for damage
and completeness.
Make sure that
– all moving parts are correctly aligned and not seized.
– that no parts are broken and that there is otherwise no damage which could
affect the operation of the tool.
• Have damaged tools repaired by specialists before using them again.
– Use only genuine spare parts from Westfalia Separator. Otherwise, the
safety of the tool can be impaired.
• Keep the tools clean and keep them in a dry, safe place.
Properly maintained and cleaned tools work more precisely and can be
checked better.

32 2065-9001-202 / 0613
• Collect dripping oil to prevent danger

of slipping or product infection.
• When handling waste oils note:
– They can be injurious to health,
depending on their chemical com-
position.
– Waste oil must be disposed of in
accordance with local regulations.
Fig. 52

2065-9001-202 / 0613 33
1.6 Corrosion
Corrosion can also affect bowl parts made of stainless steel. This corrosion can
be flat-spread or pit- or crack-shaped and merits special attention.
Corrosion on stainless steel bowl material should be examined thoroughly and
documented.
Flat-spread corrosion can usually be measured (reduction of wall thickness)
Pit- or crack-shaped corrosion cannot be measured without the risk of damage.
At the initial stage pit-shaped corrosion is generally caused by chlorine ions.
Depending on the stressing of the part, pit-shaped corrosion can result in crack-
shaped corrosion.
Possible formation of pit-shaped cor-

rosion.
Fig. 53
Such pittings can only be investigated by a materials expert.
In case of crack-shaped corrosion attack with or without superposed flat-

spread and pit-shaped corrosion on main bowl components, the machine
must be shut down immediately.
Contact your nearest Westfalia Separator representative for a thorough exami-

nation.
Pittings
Pittings which are close together or
form a linear pattern can signify crack
formation beneath the surface.
Such pittings should be investigated by
a materials expert.
Fig. 54

34 2065-9001-202 / 0613
1.7 Erosion
Erosion is caused by solid particles in the process liquid.
These solid particles grind marks into the surfaces with which they come into
contact.
The following factors favour the occurrence of erosion:
• hard solids particles
• high throughput capacities
The first signs of erosion should be carefully observed and documented. Ero-
sion can deepen rapidly, thereby weakening the bowl material.
Contact your nearest Westfalia Separator representative for a thorough exami-

nation. Information on the nature of the damage can be provided by photos,
plaster casts or lead molds.
Fig. 55
The surfaces most susceptible to erosion are:
1) the bottom of the distributor, the rising channels and the ribs,
2) the centripetal pump (cavitation),
3) all surfaces in the area of the solids discharge ports,
4) the nozzles.

2065-9001-202 / 0613 35
Signs of erosion which you should

immediately report to your nearest
Westfalia Separator representative:
• The bottom of the erosion mark has
a radius smaller than 1 mm (large
notch effect).
• The depth of erosion mark exceeds
1 mm (0.04 inch) at the deepest
point.
Fig. 56

36 2065-9001-202 / 0613
1.8 The health hazards involved when handling heavy oils and lube oils
As a result of the deterioration in quality of fuel oils, the danger has arisen that the heavy oils used on
board contain greater amounts of substances injurious to health. These include:
- polycyclic aromatic hydrocarbons,
- lead compounds,
- chemical residues.
An increased amount of polycyclic aromatic hydrocarbons is also present in used lube oils (waste oils).
The health hazards for the engine room staff depend to a large extent
• on the concentrations of the dangerous substances,
• the ambient air (inhalation of oil vapours/oil mist),
• the intensity and duration of the contact with the skin or mucous membrane.
Possible short-term effects:

• headaches,
• dizziness,
• nausea,
• itching or burning of the skin,
Possible long-term effects:

• allergic reactions, especially skin allergies,
• festering inflammation of the skin pores (oil-acne),
• damage to the central nervous system after inhalation over a long period,
• skin cancer caused by direct skin contact over a long period,
• Lung cancer or cancer of the digestive organs after inhalation over a long period
(not certain as the causes are difficult to separate from the effects of smoking and alcohol).
1.8.1 Code of practice and personal protective measures
• Avoid skin contact with heavy oils or lube oils if possible!

- Wear suitable protective gloves.
- Apply a protective ointment to the skin (e.g. ointment no. 76), especially if no protective gloves are
worn!
• Avoid breathing in oil vapours if possible!
• If possible, improve the air circulation in the room!
Fully open the air regulation flaps in the outlets of the air supply ducts in the centrifuge and filter area.
• Wash affected areas of skin frequently and thoroughly!
Apply protective ointment to the skin!
• Personal hygiene is of the utmost importance!
• Change dirty overalls regularly!
• Exercise special care when carrying out maintenance work on and cleaning heavy oil and lube oil cen-
trifuges and filters!

2065-9001-202 / 0613 37
2 Machine description
2.1 Dimensioned drawing of the separator .................................................. 38

2.2 General .................................................................................................. 38
2.3 Separator ............................................................................................... 38
2.4 Main components of the separator ........................................................ 41
2.4.1 Centripetal pump ................................................................................... 42
2.4.2 Bowl ....................................................................................................... 43
2.4.3 Bowl hydraulics ...................................................................................... 44
2.4.4 Drive ....................................................................................................... 47
2.5 Regulating ring ....................................................................................... 50
2.5.1 Determination by table ........................................................................... 50
2.5.2 Determination by experiment ................................................................. 51
2.6 Supervisory equipment .......................................................................... 52
2.6.1 Pressure transmitter .............................................................................. 52
2.6.2 Vibration monitoring (Option) ................................................................. 53
2.6.3 Speed monitoring ................................................................................... 54
2.7 Product feed line and product discharge line ........................................ 55
2.7.1 Throughput monitoring (product feed line A) ......................................... 55
2.7.2 Throughput determination (product feed line A) –
only for control D10 ................................................................................ 56
2.7.3 Pressure monitoring (product discharge line B) .................................... 57
2.8 Standard tools ........................................................................................ 58
2.9 Special tools .......................................................................................... 60
2.9.1 Using load-carrying equipment safely ................................................... 62
2.9.2 Safely using eyebolts and ring nuts as load-carrying equipment. ......... 62
2.10 Technical data ....................................................................................... 64
2.11 Screw torques ........................................................................................ 66
2.11.1 Screw torques in Newton meters (Nm).................................................. 66
2.11.2 Screw tightening torques in inch-pound (inlb) ....................................... 67

38 2065-9001-202 / 0613
2.1 Dimensioned drawing of the separator

• Refer to the project-specific dimensioned drawing.
• Pay attention to the installation guidelines.
2.2 General
The machine described in this manual is a high-speed centrifugal separator with
self-cleaning bowl.
"Separation" means the separation of liquid mixtures which consist of two liq-
uids, with simultaneous removal of the solids contained in the liquids.
"Clarification" is the removal of solids from a liquid.
Prerequisite for treatment technology (separation) is that the components of the
product
– can be separated mechanically,
– have different densities and
– do not emulsify.
2.3 Separator
The separator
• is equipped with a self-cleaning disk bowl,
• is used for clarification and separation in fuel and lube oil treatment plants.
• operates with regulating rings (see section 2.5).
The most important part of the separator is the bowl. The bowl
• is configured as a purifier bowl at the factory,
• can – depending on the application – be converted to function as a clarifier or
purifier bowl.
Conversion of the purifier bowl into a clarifier bowl is possible in a few simple
steps (see diagrams).
In the case of the purifier bowl:

• Mount the centripetal pump chamber
cover with bores.
IMPORTANT: All holes of the cen-
tripetal pump chamber cover must
be open!
• Select the regulating ring (see sec-
tion 2.5).
Fig. 57 Centripetal pump chamber cover

with 2 bores (example)

2065-9001-202 / 0613 39
In the case of the clarifier bowl:

• ATTENTION! Mount the centripetal
pump chamber cover (without
bores!) for operation in clarifier
mode.
• Request the part number of the cen-
tripetal pump chamber cover from
the supplier.
Fig. 58 Centripetal pump chamber cover

without bores (example)
Operating principles of the separator
Fig. 59 Example of monitoring
1 Dirty oil feed 11 Separating disk

2 Clean oil discharge 12 Solids holding space
3 Displacement water 13 Dirty water discharge
4 Pressure transmitter (product discharge) 14 Operating water discharge
5 Pressure transmitter (water discharge) 15 Solids discharge
6 Throttle 16 Operating water feed
7 Regulating ring 17 Solenoid valve block
8 Control unit
9 Sensing liquid pump (dirty water)
10 Centripetal pump (clean oil)
The fuel oil or lube oil is conveyed to the separator via a separate pump.
The product is fed in through a closed line system (1).
The dirty water is discharged (13) by sensing liquid pump (9) via a throttle (6).
The clarified clean oil is discharged (2) under pressure by centripetal pump (10).

40 2065-9001-202 / 0613
The bowl is automatically opened and closed for desludging at full bowl speed
by means of a remote controlled solenoid valve (17) in the operating water line.
The opening time of the solenoid valve is up to 3 seconds.
The control and monitoring unit (8) ensures unmanned operation.

2065-9001-202 / 0613 41
2.4 Main components of the separator
Fig. 60
Pos. Designation Function

1 Handle connection • connects centripetal pump and hood.
piece • holds the filling and displacement water supply
line.
2 Centripetal pump See section 2.4.1

Sensing liquid pump
3 Hood • covers the rotating bowl.
• holds the feed and discharges (see sec-
tion 2.7).
4 Bowl: See section 2.4.2

Bowl hydraulics See section 2.4.3
5 Frame • contains the drive parts.

• supports motor, bowl and hood.
6 Sight glass allows checking the oil level.
7 Sight glass for checking the drive belt.
8 Solenoid valve block See section 2.4.5
9 Drive See section 2.4.4
10 Motor • accelerates the separator to the required

speed.
• is protected against overload during operation.

42 2065-9001-202 / 0613
2.4.1 Centripetal pump
Fig. 61
1 Centripetal pump • discharges the purified liquid under pressure.

• is firmly connected to hood 2 of the separator.
• The disk provided with channels

dips into the liquid rotating with the
bowl.
• The liquid
– is pared off by the centripetal
pump and
– flows through its spiral channels
from the outside to the inside.
By this means the kinetic energy is
converted into pressure energy
which makes possible discharging
the liquid under pressure.
3 Sensing liquid pump • operates on the same principle as centripetal

pump 1.
• conveys the sensing liquid to the monitoring
system.

2065-9001-202 / 0613 43
2.4.2 Bowl
Fig. 62

1 Bowl produces high centrifugal forces through rotation
making possible separation and clarification.
2 Distributor accelerates the product fed in through feed A to
the rotational velocity of the bowl and then con-
veys it into the disk stack.
3 Disk stack • splits the liquid mixture consisting of a light
and heavy phase, e.g. oil-water, into its com-
ponents.
• consists of a large number of conical disks
positioned on top of one another.
Each disk is provided with spacers so that pre-
cisely defined interspaces are formed between
the individual disks.
The smooth disk surfaces facilitate sliding of the
solids and hence self-cleaning of the disks.
Separation chamber The separation space consists of a large number
of parallel chambers of low height. This produc-
es very small radial sedimentation paths for the
product.
Solids collect on the upper wall of each disk interspace

and slide down into the solids holding space.
4 Solids holding space collects the solids separated in the disk stack.

44 2065-9001-202 / 0613
2.4.3 Bowl hydraulics
A B
Fig. 63
A Separation – Bowl closed

B Ejection – Bowl open
1 Operating liquid In the rotating bowl the incoming, rotating oper-

(usually water) ating liquid generates a high centrifugal pres-
sure. This pressure is utilised for actuating the
annular piston and sliding piston which closes
and opens the bowl.
2 Annular piston • is inside the bowl bottom,

• rotates with the same angular velocity as the
other bowl parts,
• is axially movable.
3 Sliding piston • is located inside the bowl bottom,

• rotates with the same angular velocity as the
other bowl parts,
• is axially movable.

2065-9001-202 / 0613 45
Closing the bowl (separation)
A B
Fig. 64

After starting the separator the solenoid valve for operating liquid is actuated
with the aid of the control unit, and the bowl is closed as follows:
1 Operating liquid • flows into the injection chamber 4 of bowl

bottom 5 and
• from there through feed holes into closing
chamber 6.
This initiates closing of the bowl.
2 Annular piston • moves into closed position.
3 Sliding piston • is raised due to the hydrostatic pressure in

closing chamber 6.
• is pressed against the gasket 7 of bowl top
due to the hydrostatic pressure and
• closes the bowl.

46 2065-9001-202 / 0613
Opening the bowl (ejection)
A B
Fig. 65

The solenoid valve for operating liquid is opened with the aid of the control unit,
and the ejection cycle is triggered as follows:
1 Operating liquid • flows first into injection chamber 4 and

• from there into opening chamber 8.
2 Annular piston • rises and

• empties closing chamber 6.
3 Sliding piston • moves downwards and

• opens the ejection ports in bowl bottom 5 for
the separated solids 9.

2065-9001-202 / 0613 47
2.4.4 Drive
Fig. 66

1 Drive motor drives the separator.
Power transmission to the bowl spindle is via the
centrifugal clutch to the motor belt pulley and via
the drive belt.
2 Centrifugal clutch • ensures power transmission between motor,

drive belt and spindle.
• accelerates the bowl gradually to rated
speed;
• is gentle on the drive belt and motor.
Important!
– The driving effect of new clutch shoes will
improve after several starts.
– Smoking of the centrifugal clutch during the
first few starts is perfectly normal and will dis-
appear after a short time of operation.
– Wear to the clutch shoes depends on the
number of starts and the ejection frequency
(see section 4.3.1).
3 Drive belt transfers the drive power of the drive motor 1 to

the bowl spindle 4.
Regularly check the seat and condition of the
drive belt. The inspection and replacement inter-
vals are given in the maintenance schedule
(see 4.3.1).
4 Bowl spindle supports the bowl.

48 2065-9001-202 / 0613

The solenoid valve block for operating, filling and displacement water consists of
two 2/2-way solenoid valves with servo control. They are equipped with a man-
ual override for testing purposes.
Fig. 67
10 Pressure controller 90 Diaphragm

20 Sleeve-type ball valve 100 Magnet core
30 Pressure gauge 110 Coupler socket
40 Filter insert 130 Hose
70 Magnet coil
80 Housing A Manual override
Manual override A
ATTENTION: The manual override

can only be actuated with a screw-
driver!
1 closed
2 open
Fig. 68

2065-9001-202 / 0613 49
Adjusting the pressure setpoint

- pressure controller 10
If necessary:
• Correct the pressure setpoint by
turning the setpoint screw 1 (jaw
span 7).
Pressure setpoint correction

• Open the operating water valve
using the manual override (see Fig.
68).
Pressure setpoint is too low.

• Increase the pressure setpoint.
– Turn setpoint screw clockwise.
Pressure setpoint is too high.
• Decrease the pressure setpoint.
– Turn setpoint screw counter-
clockwise.
The adjusted pressure setpoint is indi-

cated on pressure gauge 30.
SW = jaw span
Fig. 69

50 2065-9001-202 / 0613
2.5 Regulating ring

Perfect separation of a liquid mixture is only possible when the bowl has been
correctly adapted to the density difference between the light liquid (e.g. oil) and
the heavy liquid (e.g. water).
To achieve this, select and fit the regu-

lating ring from the set furnished (with
different inner diameters) whose inner
diameter corresponds to the difference
in density between the two liquid com-
ponents.
Fig. 70 Regulating ring (example)
The inner diameter of the regulating ring to be selected can be determined from
the table or empirically. The general rule of thumb is:
• narrow regulating ring for high density of the light liquid
• wide regulating ring for low density of the light liquid
2.5.1 Determination by table
Density of the light liquid, Inner diameter

o o
at 15 C (59 F) of the regulating ring
3
kg/dm mm
0.80 – 0.81 79
0.82 – 0.86 76
0.87 – 0.89 70
0.90 – 0.92 66
0.93 – 0.96 62
0.97 – 0.991 59
Density difference of the liquids

3
Min. density difference 0,02 kg/dm
3
Max. density difference 0.20 kg/dm
3
The max. density of the light liquid is 0,991 kg/dm with a density of the heavy
3
liquid of 1.0 kg/dm .
Important!
If light liquid discharges through the heavy liquid discharge, the next smaller
regulating ring must be fitted.

2065-9001-202 / 0613 51
2.5.2 Determination by experiment

(explained using the example of oil purification)
Always try a wide regulating ring and then the next smaller ring.
When the regulating ring is too wide the discharging water contains oil.
When the regulating ring is too narrow the discharging clean oil contains water.
The water may look milky or dirty. The coloration comes from the washing of the
oil.
In the bowl, a separation zone is formed between the light and heavy phases
whose centre is the separating line.
After opening the bowl, the position of the separating zone can be recognised
by the almost always visible separating line between water and oil on the under-
side of the separating disk.
Correctly selected regulating ring

The separating line between water and
variable
oil is at the outer edge of the discs.
Effect:
– The discharging clean oil is free of
water.
– The discharging water is free of oil.
Fig. 71
Regulating ring too wide

The separating line between water and
too wide oil runs
– far outside the discs and
– too close to the outer edge of the
separating disk.
Effect:
– The discharging clean oil is free of
water.
– The discharging water contains oil or
– oil breaks the water seal.
Fig. 72
Regulating ring too narrow

too narrow The separating line between the liquid
components does not pass at the outer
edge of the discs but further inwards.
Effect:
– The discharging clean oil contains
water.
– The discharging water is free of oil.
Fig. 73

52 2065-9001-202 / 0613
2.6 Supervisory equipment

The separating process is monitored and controlled by an automatic control unit.
For further details, refer to the control unit manual.
2.6.1 Pressure transmitter
The pressure transmitters PT1 and

PT2
– serve to register alarms PAH (Pres-
sure Alarm High) and PAL (Pressure
Alarm Low),
– switch process-specifically in case of
pressure drop or increase,
– can be checked with software for
correct functioning and the switching
points can be adjusted.
– are maintenance-free.
Fig. 74
The pressure transmitter

– PT1 is fitted in the product discharge line.
– PT2 is fitted in the water discharge line.
Note:
Refer to the circuit diagram and terminal plan in the control cabinet and the
manual of the control system.
Setting the switching points

The switching points are set at the factory using appropriate software.
Factory settings
Product discharge line Water discharge line
Pressure transmitter
Pressure transmitter
PT2
PT1
PAL PAH PAH

(1) (2)
1.0 bar 3.0 bar 1.0 bar
(1)
The product discharge pressure on the pressure gauge (separator) must be 0.5 to
1 bar above the switching point.
(2)
The product discharge pressure on the pressure gauge (separator) must be 0.5 to
1 bar below the switching point.
ATTENTION:
• Pay special attention to order-specific settings (see operating data sheet in
the order documentation)!

2065-9001-202 / 0613 53
2.6.2 Vibration monitoring (Option)

The separator is protected against inadmissibly high vibrations by means of an
electronic vibration monitoring system.
Fig. 75 Installation example
1 Vibration pick-up • is installed at the upper part of the frame.

• converts the separator vibrations into electric
signals.
2 Terminal box • is mounted at the lower part of the frame.
3 Vibration monitoring • is installed in the control cabinet.
unit • evaluates the signals coming from the vibra-
tion pickup.
The evaluation of the signal – depending on the version – takes place
in the control cabinet, on the control unit or directly on the vibration
pickup.
When the limit value or values are exceeded, an alarm and follow-up
measures are triggered and the separator motor switches off automati-
cally.
The operating status can be read off on the control unit.
ATTENTION!
Pay attention to the following instructions and plans:
• instruction manual of the vibration monitoring system
• instruction manual of the control unit
• terminal allocation in the terminal diagram of the control cabinet
• circuit diagram

54 2065-9001-202 / 0613
2.6.3 Speed monitoring

The speed monitoring device
• serves to indicate the bowl speed.
Speed variations up to 5 % are admissible.
• monitors the drop in speed and exceeding the speed and starting time.
Fig. 76
1 Spindle • rotates and generates speed pulses at the

proximity switch 2.
2 Proximity switch • transmits the pulses triggered from the spindle

to the control unit 3.
IMPORTANT!
Align the proximity switch as illustrated.
The distance X between spindle and proximity
switch must be 3.5 mm.
3 Control unit • evaluates the speed pulses.

• triggers an alarm if the bowl speed is too low
or too high.
• initiates a shut-down process if the bowl speed
is too low or too high.
• indicates the current bowl speed and
• permits setting of limit values.
IMPORTANT!
Pay attention to the terminal allocation in the terminal diagram of the
control cabinet and refer to the instruction manual of the control unit.

2065-9001-202 / 0613 55
2.7 Product feed line and product discharge line
Fig. 77
The separator is adapted to local conditions for throughput capacity and line
pressure by means of orifice plates installed in product feed line A and product
discharge line B (see section 4.2).
2.7.1 Throughput monitoring (product feed line A)

The effective throughput capacity of the separator is stated on the project de-
pendent data sheet.
The inner diameters of the orifice plates required for the different throughput ca-
pacities can be read from the following table:
Flowmeter – Scale: 0 – 10
Throughput capacity Inner diameter of orifice plate
[l/h] [mm]
1 000 – 1 400 6
1 400 – 2 200 8
2 200 – 3 300 10
3 300 – 4 800 12
4 800 – 7 000 14
7 000 – 13 000 no orifice plate
When using a D10 control unit

• During commissioning mark the respective scale area on flowmeter 4
(see Fig. 77 with the sticker supplied.

56 2065-9001-202 / 0613
When using an E40 control unit

The effective throughput capacity is displaced on the control unit via the pres-
sure transmitter 5.
Throughput values deviating between the actual value and the setpoint value
can be adapted in the control unit.
2.7.2 Throughput determination (product feed line A) – only for control

D10
Fig. 78 Diagram for determining the throughput rate
A Inner diameter of orifice plate (mm)

B Throughput capacity (x 1000 l/h)
C Scale area of flowmeter
The throughput capacity of the separator (volume of product to be treated fed by

unit of time) can be determined with the aid of the diagram.
3/2-way valve with flow indicator 4

Procedure:
• Read the value on the scale of flowmeter 4 (see Fig. 77).
e.g. 3
• From the value read from the scale (e.g. 3) draw a line up to the curve of the
inner diameter of the built-in orifice plate A (e.g. Ø 10).
• Read the throughput rate B appearing vertically below:
e.g. 2.7 (= 2 700 l/h)
The precision in throughput determination depends on the following characteris-
tics of the product to be processed:
– Viscosity
– Temperature
– Density
The parameters mentioned here can lead to inexact determination of the
throughput rate.

2065-9001-202 / 0613 57
2.7.3 Pressure monitoring (product discharge line B)

The pressure in the discharge line is displayed on pressure gauge 1 (see Fig.
77).
• Note factory adjusted switch points (see section 2.6.1).
The inner diameters of the orifice plates required for the different throughput ca-
pacities can be read from the following table:
Pressure gauge - Measuring range: 0 – 10 bar

Throughput capacity Inner diameter of orifice plate
[l/h] [mm]
1 000 – 1 800 6
1 800 – 2 800 8
2 800 – 4 300 10
4 300 – 6 300 12
6 300 – 9 100 14
9 100 – 13 000 no orifice plate

58 2065-9001-202 / 0613
2.8 Standard tools

are commercially available tools to be supplied by the customer.
Fig. 79

2065-9001-202 / 0613 59
Item Designation
1 Screwdriver
2 Torque wrench (0 – 100 Nm)
with inserts and extension
3 Calliper gauge
4 Electric oil heater for ball bearings
5 Ratchet
with inserts and extension
6 Standard hammer and mallet
7 Inner snap pliers with offset jaws (Ø 40 mm)
8 Outer snap pliers (Ø 35 mm)
9 Hand-held speedometer
10 Wrench, adjustable
11 Brushes
12 Pulling device (200 x 200 mm (H x W))
13 Open-ended wrench (jaw spans: 19, 32, 55 mm)
14 Hardwood blocks
15 Drill
16 Drill bit (Ø 2 mm)
17 Wood screws (max. Ø 4 mm x 50 mm length)
18 Allen screws (M 8 x 20)

60 2065-9001-202 / 0613
2.9 Special tools
Fig. 80

2065-9001-202 / 0613 61
• Special tools are provided by the manufacturer.

• For the delivery of special tools, the packing list supplied with the sepa-
rator is applicable.
Pos. Designation
10 Mallet
15 Complete socket wrench (spindle screw)
20 Offset screwdriver (centripetal pump)
30 Double hook wrench (centripetal pump chamber lock ring)
40 Hexagon nut M 10 (centrifugal clutch)
50 Hex head screw M 10 x 200 (centrifugal clutch)
60 Disk (centrifugal clutch)
70 Eye bolt, complete (bowl / centrifugal clutch))
80 Bell-shaped piece (bowl top / disk stack / sliding piston)
90 Assembling device, complete (closing chamber bottom / annular pis-

ton)
100 Ring spanner (bowl top)
110 Mounting ring (annular piston)
120 Double nipple (transporting the separator)
130 Allen screw M 10 x 20 (centrifugal clutch)
140 Disk (centrifugal clutch)
150 Pressure piece (centripetal pump)

62 2065-9001-202 / 0613
2.9.1 Using load-carrying equipment safely

• Use only load-carrying equipment with nameplate.
The nameplate attached to the load-

carrying equipment shows the follow-
ing data:
– CE label
– Manufacturer
– Year of manufacture
– Part number
– Intended use
– Maximum load
– Dead weight
Fig. 81 Example of a nameplate
• Use load-carrying equipment only as described in this instruction manual.

• Observe the admissible load limit.
• Before use, check the load-carrying equipment for visible damage.
– Use only intact and functional load-carrying equipment.
– Do not carry out repairs.
– Send damaged load-carrying equipment to the manufacturer.
• Always screw in threaded rods as far as they will go.
• Tighten all nuts firmly.
• Tighten all screws firmly.
• Do not step under suspended loads.
• Have all load-carrying equipment checked at least once a year by a compe-
tent person.
2.9.2 Safely using eyebolts and ring nuts as load-carrying equipment.

Improper use of eyebolts and ring nuts during transport can result in serious ac-
cidents, e.g. due to overload.
CAUTION Deformed eyebolts or ring nuts from overload!
Danger to life and limb from falling load if eyebolts or ring nuts break off.
To avoid accidents, observe the following points:
• When operating hoists, comply with relevant standards and guidelines for op-
erating load-carrying equipment issued by national organisations of the coun-
try where the equipment is operated.
• Only trained and qualified staff are permitted to install eyebolts or ring nuts.

2065-9001-202 / 0613 63
• Install eye bolts or ring nuts as illus-

trated.
• Screw in eyebolts or ring nuts com-
pletely.
• Fasten load-carrying equipment as
vertically as possible, e.g., chains.
– Maximum hoisting incline of 45°.
– Attachment methods other than
the illustrated methods, e.g. lateral
pull, are not permitted.
Fig. 82

64 2065-9001-202 / 0613
2.10 Technical data

The order-specific process data are given on the operating data sheet in-
cluded in the documentation.
Bowl
3
Solids holding space (total) 0.9 dm
–1
Speed 12 000 min
– for densities of the product up to
3 o (see name-plate)
0.991 kg/dm (at 15 C) and
– for densities of the separated solids up to
3
1.4 kg/dm
Speed for higher densities contact the factory
Starting time approx. 2 – 4 min

Run-down time (after switching off the motor
45 min
with drive belt))
Run-down time (without drive belts, i.e. in
the case of torn, jumped off or defective drive 90 min
belt)
Centripetal pump
Pressure head 1 – 2 bar
Operating water
Qty. min. 1 800 l/h
Pressure (with open valve) 2 – 3 bar
Standard operating water specification
Suspended matter max. 10 mg/l

Particle size max. 50 µm
Hardness:
o o
– up to 55 C separating temperature < 12 dH
o o
– above 55 C separating temperature < 6 dH
To convert the hardness values stated use the following equation:
1° dH = 1.79 ° fH = 1.25 ° eH = 17.9 ppm CaCO3
Chlorine ions < 100 mg/l
pH 6.5 – 7.5

2065-9001-202 / 0613 65
Normal separating temperature of the product
DO 20 °C (68 °F)
MDO 40 °C (104 °F)
LO 90 °C (194 °F)
LO HD 95 °C (203 °F)
HFO 98 °C (208 °F)

Due to the large number of products to be treated, it is not possible
to specify an exact separating temperature of the product in this
manual.
The exact separating temperature of the product (in °C) is stated in
the order-specific data sheet.
Motor
Power rating 50 Hz 4 kW
60 Hz 4.8 kW
Speed 50 Hz 3 000 RPM

60 Hz 3 600 RPM
Design IM V1
Enclosure IP 55
Drive 50/60 Hz
Oil filling approx. 2.5 l
Oil quality, see section 4.3.3
Product feed pump
Pump unit (gear or screw pump)
Output depending on plant rating
Suction height max. 0.4 bar
Pressure head 2 bar
Weights
Separator (with motor, without bowl) 160 kg

Bowl 45 kg
Motor 25 kg

66 2065-9001-202 / 0613
2.11 Screw torques

The torques apply for:
• metric screws with coarse-pitch thread.
– hex head screws according to DIN EN ISO 4014
– Allen screws according to DIN EN ISO 4762
• through holes according to DIN ISO 20273 (medium).
• greased screws (coefficient of friction = 0.10).
• torque wrench with a tolerance of ±10 %.
• the material combination steel - steel or stainless steel.
IMPORTANT: Severe damage to or destruction of the separator due to

incorrect torques!
• Select the correct torques for screwed connections.
Screws whose torque deviates from the following table are marked with the
required torque in the manual.
2.11.1 Screw torques in Newton meters (Nm)
Extract from the works standard WSN 19-0019-00

A2–70
Property class 8.8 10.9 12.9
A4–70
Yield strength/ 640/ 450/
2 940 1100
Proof stress [N/mm ] 660 250
Pitch Thread size Torques [Nm]
0.70 M4 2.6 3.9 4.5 1.9 M4
0.80 M5 5.2 7.6 8.9 3.6 M5
1.00 M6 9.0 13.2 15.4 6.3 M6
1.25 M8 21.6 31.8 37.2 15.2 M8
1.50 M 10 43.0 63.0 73.0 30.0 M 10
1.75 M 12 73.0 108.0 126.0 52.0 M 12
2.00 M 16 180.0 264.0 309.0 126.0 M 16
2.50 M 20 363.0 517.0 605.0 248.0 M 20
3.00 M 24 625.0 890.0 1041.0 237.0 M 24
3.50 M 30 1246.0 1795.0 2077.0 472.0 M 30
4.00 M 36 2164.0 3082.0 3607.0 - M 36

2065-9001-202 / 0613 67
2.11.2 Screw tightening torques in inch-pound (inlb)

The following formula is used to convert the torques (Ma) from “Nm“ to “inlb“:
Mainlb = MaNm x 8.85
Example:
Mainlb = Wanted (screw torque in “inch-pound“)

MaNm = 50 (screw torque in “Newton meters“)
Mainlb = 50 Nm x 8.85
Mainlb = 442.5 inlb
Extract from the works standard WSN 19-0019-00

A2–70
Property class 8.8 10.9 12.9
A4–70
Yield strength/ 640/ 450/
2 940 1100
Proof stress [N/mm ] 660 250
Thread di-
Pitch Torques [inlb]
ameter
0.70 M4 23.0 34.5 39.8 16.8 M4
0.80 M5 46.0 67.3 78.8 31.9 M5
1.00 M6 79.7 116.8 136.3 55.8 M6
1.25 M8 191.2 281.5 329.3 134.5 M8
1.50 M 10 380.6 557.6 646.1 265.5 M 10
1.75 M 12 646.1 955.9 1115.2 460.3 M 12
2.00 M 16 1593.2 2336.7 2735.0 1115.2 M 16
2.50 M 20 3212.9 4576.0 5354.9 2195.0 M 20
3.00 M 24 5531.9 7877.4 9213.9 2097.7 M 24
3.50 M 30 11028.3 15887.5 18383.5 4177.7 M 30
4.00 M 36 19153.6 27278.8 31925.6 - M 36

68 2065-9001-202 / 0613
Note
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2065-9001-202 / 0613 69
3 Operation
3.1 Technical information ............................................................................. 70

3.1.1 Separation.............................................................................................. 70
3.1.2 General information on bowl ejection .................................................... 70
3.2 Before start-up ....................................................................................... 72
3.2.1 Before the first start-up – after maintenance and repair ........................ 72
3.2.2 Before every start-up ............................................................................. 74
3.3 Starting the separator ............................................................................ 75
3.4 Monitoring of operation .......................................................................... 77
3.5 Setting the separation time .................................................................... 78
3.5.1 Mathematical calculation ....................................................................... 78
3.6 Bowl ejection .......................................................................................... 79
3.7 Shutting down the separator .................................................................. 80
3.7.1 Shut-down “Emergency-Off" .................................................................. 82
3.8 Trouble shooting .................................................................................... 84
3.8.1 Trouble shooting .................................................................................... 84
3.8.2 Bowl faults.............................................................................................. 86

70 2065-9001-202 / 0613
3.1 Technical information

Take note of the following sections:
3.1.1 Separation
The best separation effect is obtained with low viscosity of the product to be
separated.
The separator operates economically with the separating temperatures and ca-
pacities specified by us. Refer to the data sheet and contractual agreements.
Procedure:
• Select the desired operating mode on the control unit.
• Set the separating time on the control unit.
• Start the separator (see 3.2).
3.1.2 General information on bowl ejection

The bowl is ejected automatically at full speed during the program sequence.
The ejection time is determined by the preset separating time.
For determining the separating time, see 3.5.
Sequence of an ejection (example)

1. Separating time has elapsed.
2. Product feed valve is closed.
3. Displacement water displaces the fuel oil to the clean oil side.
4. Operating water opens and closes the bowl hydraulically at full bowl
speed.
5. Waiting time for speed recovery.
6. Filling water supply.
7. Product valve is opened.
8. Separating time resumes.
Displacement (option)
• When separating, the loss of feed liquid unavoidable during ejection can be
reduced to a minimum by displacing the feed liquid with water before sludge
ejection takes place (especially important when processing valuable feed liq-
uid).
• The duration of displacement water supply is given in the timer overview (see
control unit manual).
• If the displacement time is too long, water will discharge through the light liq-
uid outlet.
• If the displacement time is too short, part of the product remains in the bowl
and is lost during desludging.

2065-9001-202 / 0613 71
Flush ejection
If the solids cant be completely ejected,
– due to an excessively long dwell time in the bowl or
– are stuck to firmly on the wall of the solids holding space due to the solids
properties,
• either the separating time must be shortened or
• a flush ejection must be carried out after the total ejection by filling the bowl
with water or product and emptying it again.
Program control
• "Displacement", "ejection", "filling" and "flush ejections" at precisely defined
intervals are best carried out with the automatic control unit.
• The clean oil discharge and water discharge can be monitored.
• Faults can be signalled visually or audibly.

72 2065-9001-202 / 0613
3.2 Before start-up
Note:
• Safety precautions in chapter 1.
• Instruction manual of the corresponding control unit.
• Instructions “Settings and malfunctions”
• Instruction manuals for other auxiliary equipment
• Process-related deviations are possible
(refer to the order-specific operating data sheet!)
3.2.1 Before the first start-up – after maintenance and repair
CAUTION: Danger to operating safety of the separator as a result of long

standstill or storage times!
– Observe the recommended maintenance intervals.
If the bowl has been opened for longer than 6 months,
• check all bowl parts in accordance with the maintenance schedule and re-
place when necessary.
– See table "Maintenance every 4000 operating hours – after no more than
6 months at the latest".
If the bowl has been out of operation for longer than 12 months,
• check all separator parts in accordance with the maintenance schedule and
replace when necessary.
– See table "Maintenance every 8000 operating hours – after no more than
1 year at the latest".
• replace all separator parts in accordance with the maintenance schedule.
– See table "Maintenance after 8000 operating hours – after 1 year at the lat-
est".
Ensure that
• the sight glass in the frame for observing the drive belt is clean.
• the sight glass in the frame for observing the oil level is clean.
• the drive chamber is filled with oil in accordance with section 4.3.3.
• the cover for the lower section of the frame is correctly mounted.
• the bowl height is correct (see 4.7.1).
• the bowl can be rotated by hand.
• The machine has been correctly assembled.
– Tighten the bowl top securely (left-hand thread).
– Tighten the spindle screw to the separator-specific torque (left-hand
thread).
– Tighten the centripetal pump lock ring tightly (left-hand thread).
• the hood is correctly mounted (see 4.5).
• the handle connection piece is tightly bolted to the centripetal pump (see 4.5).
• the hoses and hose pipes are not damaged and connected (see 4.3.2).

2065-9001-202 / 0613 73
• the feed and discharge lines are connected (see 4.5).

• the monitoring equipment is complete as well as mechanically and electrically
functional.
• the product and supply lines are operational.
– Pay attention to air and water pressures (see order-specific operating data
sheet).
• the product heating devices are ready for operation (optional).
– Pay attention to volumes, pressure and temperature (see order-specific op-
erating data sheet).
• Ensure that installation components such as valves, water pressure reducer,
maintenance unit, etc. are operational.
• the motor is correctly connected (see 4.1.3).
• the motor is correctly mounted.
Important!
• Check the remaining unit components such as hose pipes, sight glasses, etc.
for signs of ageing and mechanical damage.
• Replace damaged installation components with new parts immediately.

74 2065-9001-202 / 0613
3.2.2 Before every start-up
Ensure that
• the sight glass in the frame for observing the drive belt is clean.
• the sight glass in the frame for observing the oil level is clean.
• the drive chamber is filled with oil in accordance with section 4.3.3.
• the machine is correctly assembled.
– Tighten the bowl top firmly (left-hand thread).
– Tighten the spindle screw with the separator-specific torque (left-hand
thread).
– Tighten the centripetal pump chamber lock ring securely (left-hand
thread).
• the hood is correctly mounted (see 4.5).
• the handle connection piece is tightly attached to the centripetal pump
(see 4.5).
• the hoses and hose pipes are undamaged and connected (see section 4.3.2).
• the feed and discharge lines are connected (see 4.5).
• the monitoring equipment is complete as well as mechanically and electrically
functional.
• the product and supply lines are ready for operation.
– Pay attention to air and water pressures (see order-specific operating data
sheet).
• the product heating devices are ready for operation (optional).
– Pay attention to volumes, pressure and temperature (see order-specific op-
erating data sheet).
• the unit components such as valves, water pressure reducer, maintenance
unit, etc. are operational.
• the motor is correctly mounted.
Important!
• Check the remaining unit components such as hose pipes, sight glasses, etc.
for signs of ageing and mechanical damage.
• Damaged plant components must be replaced immediately by new parts.

2065-9001-202 / 0613 75
3.3 Starting the separator

• See section 3.2.1 or 3.2.2.
• Switch on control unit.
• Switch on the separator motor.
Compare the starting current and starting time with the diagram
tion 4.1.3) until the bowl reaches the speed specified on the separator name-
plate.
Note on control system D10:
The run-up phase of the separator motor is signalled by slow flashing of the
LED in the “Status Separator” key.
Note on control system E40:
The run-up phase of the separator motor is displayed by a graphical repre-
sentation of the separator motor in the control unit. Refer to the graphic repre-
sentation for "motor run-up and post-run" in the control unit manual.
ATTENTION! Before the first start-up – after maintenance and repair work
on the separator –
• check the direction of rotation of the bowl.
The bowl must run clockwise viewed from above.
The direction of rotation of the bowl is

correct if the drive belt is turning
clockwise (observe through the sight
glass in the frame).
When the direction of rotation is incor-
rect the motor connections must be
reversed by an authorised specialist.
Fig. 83
• Switch on the product feed pump (option).

– Ensure that the product feed valves to the suction and pressure sides are
open!
ATTENTION! Before the first start-up – after maintenance and repair work
on the product feed pump –
• Check the direction of rotation of the product feed pump.
The direction of rotation of the product feed pump is correct when the fan
wheel of the pump motor rotates clockwise.
• Put the preheater in operation (option).
Pre-conditions:
– Steam or thermal oil feed and discharge valves are open!
– Electric preheater is switched on!
• Open the product discharge valve in the product discharge line (option).

76 2065-9001-202 / 0613
• Open the shut-off flap in the solids

discharge (option).
1 Shut-off flap
2 Solids tank
3 Solids discharge
Fig. 84
• Start the program.

Pre-conditions:
– Continuous lighting of the LED in the “Status Separator” button.
– The specified separating temperature has been reached.
– The solids tank has been released (level switch LSHH).
– The solids tank is empty.
• After the product feed valve has automatically opened
– Set the backpressure in the product discharge line to approximately 1.5 bar
(see order-specific operating data sheet).
– Adjust the desired throughput capacity; while doing so, maintain the back-
pressure in the product discharge line within the specified range.
ATTENTION!
• Check solids discharge and frame drain; no oil may flow here during the sep-
arating process!

2065-9001-202 / 0613 77
3.4 Monitoring of operation

The machine is monitored largely by the separator control.
Operations to be carried out regularly:

• On your daily round, especially during the first 1500 operating hours, pay at-
tention to the following:
– Oil level
– Temperatures
– Pressures
– Leakage
– Vibrations
– Current consumption
– Starting time
– Hoses and hose pipes
– Pipe joints
• Keep to the maintenance schedule (see 4.3.1)!
• Inspection
We, therefore, recommend in your own interest to have your separator in-
spected by our service engineers once a year. These checks help to
– maintain the operating safety of the machine and
– avoid unscheduled downtime.
Im p o rta n t!
• Regularly check plant components such as hose pipes, sight glasses for signs
of aging and mechanical damage.
• Damaged plant components must be replaced immediately by new parts.

78 2065-9001-202 / 0613
3.5 Setting the separation time

When using time-dependent automatic control programs, accurate setting of the
separation time (time between ejection cycles) is only possible if the throughput
capacity and solids loading in the feed remain constant. If this is not the case, it
may be necessary to correct the settings during operation.
The separating time depends on
• the preselected operating mode (partial or total ejection mode),
• the solids loading in the feed,
• the consistency of the solids,
• the effective solids space volume in the bowl,
• the separator throughput.
Given constant conditions, the separating time can be determined by calcula-
tion.
The following times have proven appropriate in practice (examples):
Product Total ejection Partial ejection

HFO max. 2 h max. 1 h
MDO max. 2 h max. 1 h
DO max. 4 h max. 2 h
LO mild max. 4 h max. 2 h
LO HD max. 2 h max. 1 h
3.5.1 Mathematical calculation

Example for mathematical calculation of the separating time:
(1)
Given: Solid content p = 0,05 %
Solids holding space volume V = 0.9 l
Solids holding space given 75 % utilisation V' = 0.675 l

(1)
Throughput capacity Vo = 2 000 l/h
Wanted: Separating time t = ? min
The separating time to be set is calculated as follows:
V’ 0.675
t = ——— • 60 • 100 = —————— • 6 000 = 40.5 min = 0.7 h
V° • p 2 000 • 0,05
(1)
Solids content and throughput capacity must be determined on site or taken from
the order specification.

2065-9001-202 / 0613 79
3.6 Bowl ejection
Automatic operation
• Initiate ejection program by pressing the “Process START” key:

– Product feed is closed process-dependent).
– Displacement (process-dependent)
– Bowl ejection
– Speed recovery
– Filling water (process-dependent)
• The product valve opens again.
Manual operation (in the case of unscheduled shut-down)
• Close the product feed line.

– Close the product feed valve manually.
• Bowl ejection:
– Open the operating liquid valve using the manual override for
approx. 2 – 3 secs.
• Speed recovery
– Wait for approx. 20 – 30 seconds.
• New separating operation
– Open the product feed valve manually.

80 2065-9001-202 / 0613
3.7 Shutting down the separator
Automatic operation
• End the separation program with the key “Process STOP”.

– Two total ejections are performed automatically.
Manual operation (in the case of unscheduled shut–down)
• Switch off the preheater (option).

– Continue to feed product for a few minutes since the preheater continues
to heat for a short time.
• Close the product feed line.
– Close the product feed valve manually.
• Displacement:
– Open the displacement water valve using the manual override.
(The bowl contents are displaced without loss by opening the displace-
ment water valve).
• Eject the bowl:
– Open the operating liquid valve using the manual override for
approx. 2 – 3 seconds.
• Speed recovery
– Wait for approx. 20 – 30 seconds.
• Switch off the product feed pump (option).

– The product feed pump continues to run (timer 23)!
– The LED in the “FEED” button shows the post-run phase by slow flashing.
– The control valves for thermal oil and steam preheater close automatically.
ATTENTION!
If the control unit or the control voltage 24 VDC fails, the automatic post-run
phase of the product feed pump is disabled.
The product feed pump may never be switched off to the steam shut-off valve
without a delay time. The pre-heater could get damaged!
All heaters (e.g. steam-fired, thermal oil, electric heaters) must be manually
shut down.
Manual shut-down of the product feed pump must be carried out delayed.
• Close the product feed valve in the suction side of the product feed pump (op-
tion).
• Switch the separator motor off.
• Close the discharges.
• Close the supply lines such as heating steam, water, compressed air lines
with hand valves.
CAUTION: Danger to life through high-speed rotating separator parts!

• Do not loosen any part of the separator before the bowl has come to a stand-
still.
– The run-down time of the bowl is 45 minutes after switching off the motor.
– Bowl standstill is indicated by standstill of the drive belt.

2065-9001-202 / 0613 81
Standstill of drive belt

• Shine a torch through the frame
sight glass.
• Visually check that the drive belt is
no longer moving.
Fig. 85
When the sight glass is turbid:

• Unscrew the sight glass,
• shine a torch through the sight glass opening in the frame!
CAUTION: Danger of injury through rotating drive belt!
• Check ONLY visually that the drive belt is no longer moving.
– Do NOT touch the drive belt through the sight glass opening in the frame!
• Clean the sight glass and screw it back in.
CAUTION: Danger to life through high-speed rotating separator parts!

In the case of torn or defective drive belts or if the belts have come off:
still.
• Be sure to observe the run-down time of 90 minutes until dismantling the
separator!
ATTENTION!
Only after standstill of the bowl,
• Close the shut-off flap in the solids
discharge (option).
1 Shut-off flap
2 Solids tank
3 Solids discharge
Fig. 86
Risk of injury due to electrical volt-

age and unintended start-up of the
separator!

ponents:
Fig. 87

82 2065-9001-202 / 0613
CAUTION: Danger of injury through very hot separator parts!

When carrying out maintenance work, there is a danger of injury through hot
o o
separator parts (separating temperatures of 70 to 100 C (158 – 212 F)).
3.7.1 Shut-down “Emergency-Off"

In a hazardous situation (unusual noises or vibrations) or in the case of damage
to the separator or plant components (e.g. burst hoses), a manual quick shut-
down of the installation can be carried out.
Depending on the version, the control cabinet is equipped with:
– a main switch (yellow-red) with integrated “Emergency-Off” function and
additional connection for an external “Emergency-Off”-switch (example 1),
– an “Emergency-Off” switch (yellow-red), a main switch (grey-black) and ad-
ditional connection for an external “Emergency-Off”-switch (example 2) or
– an “Emergency-Off” switch (yellow-red), a main switch (grey-black) and ad-
ditional connection, via approved “Emergency-Off” relay for several “Emer-
gency-Off”-switches (example 2).
Main switch (yellow-red) with inte-

grated “Emergency-Off” function
• Actuate the main switch with “Emer-
gency-Off” function.
– The complete control unit is de-
energised.
– No bowl ejection is performed.
• CAUTION! Evacuate the room.

Fig. 88 Example 1
“Emergency-Off”-switch (yellow-
red) and main switch (grey-black)
• Actuate the “Emergency-Off switch.
– The complete drives of the control
unit are de-energised.
– The separator is shut down in a
controlled manner with two total
ejections.
• CAUTION! Evacuate the room.

Fig. 89 Example 2

2065-9001-202 / 0613 83
Note
注释
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84 2065-9001-202 / 0613
3.8 Trouble shooting

The following tables are an aid for locating and eliminating faults.
If assembly operations have to be carried out refer to the section "Maintenance
and Repair".
3.8.1 Trouble shooting
Failure Possible causes Action

The bowl does not come up Oil has run down the spindle onto the • Clean belt contact surface of the
to rated speed or takes too drive belt; the drive belt is slipping on spindle and clutch pulley.
long to do so. the bowl spindle. • Replace the drive belt.
Motor is incorrectly connected. • Check connection.

Insufficient number of clutch shoes. • Increase the number of clutch
shoes.
• Make sure that the
clutch shoes are
evenly spaced.
Drive belt has stretched and is slipping • Replace drive belt.

on the bowl spindle.
Drive belt has not been fitted correctly. • Check position of drive belt on cen-
trifugal clutch and bowl spindle.
Liquid or dirt has collected in the upper • Check operating water discharge:
section of frame and is braking the Liquid must flow off freely.
bowl. • Clean inside of upper section of
frame.
The bowl speed drops during Friction surfaces of clutch shoes are • Wipe dry friction surfaces.
operation. oily. • ATTENTION: Do not use
benzene, trichloreth-
ylene or any other sol-
vent!
Drive belt has stretched and is slipping • Replace the drive belt.
on the bowl spindle.
The motor speed drops during opera- • Check motor and line voltage.
tion.
The bowl reaches the rated Too many clutch shoes are used. • Reduce the number of clutch shoes.
speed too fast (in less than • Make sure that the
1.5 minutes). The starting clutch shoes are
current of the motor is hence evenly spaced.
inadmissibly high.(Imax >2 x IN).

2065-9001-202 / 0613 85

Uneven run of the centrifuge. Bowl is out of balance for the following For pos. 1 - 4:
reasons: • Shut down separator.
• Close the product feed and dis-
charge.
CAUTION:
• Bowl must not be emptied
as otherwise the vibrations
occurring during shut-down
will intensify.
If bowl leaks,
• Completely open the water supply.
1. The separated dirt has deposited • Clean bowl.
unevenly in the bowl.
2. Bowl has not been correctly as- • Assemble bowl properly.
sembled or parts of different bowls
(if plant has several separators)
have been interchanged.
3. The tension in the disk stack has
slackened:
– The bowl top is not screwed on CAUTION: A loose bowl
until O mark alignment. top can endanger life!
• The O marks of
the bowl bottom
and the bowl top
must be aligned.
– Insufficient number of disks. • Check number of disks; add a spare

disk if necessary.
4. Bowl parts are damaged. • Send bowl to factory for repair.
CAUTION: Do not carry out
your own repairs!
Do not weld or solder as this
would weaken the bowl!
Ball bearings are worn. • Replace damaged bearings.
ATTENTION!
Use only the ball bearings
specified in the parts list.

86 2065-9001-202 / 0613
3.8.2 Bowl faults
Fig. 90 Bowl and operating water feeding system
1 Gasket (bowl top) 11 Operating water feeding system

2 Gasket (bowl top) 12 Injection chamber
3 Gasket (sliding piston) 13 Closing chamber bottom
4 Gasket (annular piston) 14 Bowl bottom
5 Gasket (closing chamber bottom) 15 Drain hole
6 Gasket (annular piston) 16 Annular piston
7 Gaskets (closing chamber bottom) 17 Drain hole
8 Gasket (bowl bottom) 18 Sliding piston
9 Piston guide ring (bowl bottom) 19 Bowl top
10 Gasket (water chamber bottom) 20 Solenoid valve block
21 Solenoid valve for operating water
22 Solenoid valve for filling and displacement water
23 Filling and displacement water line
24 Strainer
25 Shut-off valve
26 Operating water line

2065-9001-202 / 0613 87
The bowl does not close. Operating water

Control unit is defective or • Check the control unit.
ATTENTION: Motor is not correctly set. • Check or reset program parameters.
– Product flows out of the
(See control unit documentation.)
solids discharge.
– Current consumption is too
high.
Closing water pulse too short. • Set 1 seconds (see also control unit
documentation).
Strainer 24 in the operating, filling and • Close shut-off cock 25.
displacement water line is dirty. • Clean strainer 24 (see 4.4.4).
The operating water capacity is too • Check line pressure, increase if
low. necessary.
Operating water data:

– Pressure 2 – 3 bar (with open valve)
– Volume flow min. 1 800 l/h (gauge
the capacity by litres) ≅ 1.0 l in
3 secs
The operating water line 26 has be- • Clean or replace operating water
come constricted due to dirt accumula- line 26.
tion or damage. Insufficient operating
water is entering the injection cham-
ber.
The operating water solenoid valve 21 • Check solenoid valve 21 and re-
does not open properly. place if necessary.
Bowl hydraulics
Bowl hydraulic system is soiled. • Remove hood and
or • dismantle and clean the bowl (see
section 4.4.1 and 4.4.2).
• Thoroughly clean all bores.
– Thoroughly check outlet bore 15
and clean if necessary.
Gaskets and piston guide ring are • Replace all sealing elements.
damaged or Use set of spare parts "bowl/hood“
(see list of spare parts).
Important: Time-consuming instal-
lation!
• Change polyamide gasket 5 only
when it is damaged (see
tion 4.4.9).
Sealing rim of sliding piston 18 is • Lightly remachine the sealing sur-
damaged. face of the sliding piston – max.
1 mm! – see section 4.4.10) or
• send in the sliding piston for repair.

88 2065-9001-202 / 0613

24 Strainer
25 Shut-off valve

2065-9001-202 / 0613 89
The bowl does not open or Operating water

not properly Control unit is defective or • Check the control unit.
Motor is not correctly set. • Check or reset program parameters.
(See control unit documentation.)
Time for opening water too short. • Set 3 – 4 seconds (see also control
unit documentation).
Strainer 24 in the operating, filling and • Close shut-off cock 25.
displacement water line is dirty. • Clean strainer 24 (see 4.4.4).
The operating water capacity is too • Check line pressure, increase if
low. necessary.

3 secs
The operating water line 26 has be- • Clean or replace operating water
come constricted due to dirt accumula- line 26.
tion or damage. Insufficient operating
water is entering the injection cham-
ber.
The operating water solenoid valve 21 • Check solenoid valve 21 and re-
does not open properly. place if necessary.
Bowl hydraulics
Bowl hydraulic system is soiled • Remove hood and
or • dismantle and clean the bowl (see
section 4.4.1 and 4.4.2).
• Thoroughly clean all bores.
– Thoroughly check outlet bore 17
and clean if necessary.
Gaskets and piston guide ring are • Replace all sealing elements.
damaged. Use set of spare parts "bowl/hood“
(see list of spare parts).
Important: Time-consuming instal-
lation!
• Change polyamide gasket 5 only
when it is damaged (see
tion 4.4.9).
• Thoroughly check polyamide gasket
5 for proper location in its groove.

90 2065-9001-202 / 0613

24 Strainer
25 Shut-off valve

2065-9001-202 / 0613 91

The bowl does not empty The operating water capacity is too • Check line pressure, increase if
completely. Solids remain in low. necessary.
the bowl.
3 secs
The separating time has been set too • Shorten the separating time (see
long with the result that the solids con- section 3.5).
tent is too high.
The bowl opens during sepa- Closing water pulse is too short. • Readjust the closing water impulse
ration. – Closing water evaporates. (see control unit documentation).
Closing water pulse is too long.
– Closing water impulse opens the
bowl.

92 2065-9001-202 / 0613
In case of electrical faults
CAUTION: Danger due to electrical current!

• Switch off the main switch and lock it.
• Close the main valve for operating water, filling and displacement water.

o
separator parts (separating temperatures of 70 to 100 C (158 – 212 °F)).
ATTENTION:
• Refer to the instruction manual and nameplate of the solenoid valve block.
• Direct intervention in the solenoid valve block only by authorised specialists
and with suitable tools!

Solenoid valve does not func- Control unit is defective. • Inform GEA Westfalia Separator
tion. service.
Wire break in the connecting terminal. • Replace wire.
Connecting terminal on the connector • Tighten the screw of the connect-

block is loose. ing terminal.
Bad contact on the connecting terminal. • Clean or replace the contact.
Coupler socket loose. • Tighten coupler socket.
Magnet coil defective. • Replace magnetic head.
Diaphragm defective. • Replace diaphragm.
Strainer in the operating, filling and • Close the shut-off valve.

displacement water line is dirty. • Clean strainer (see 4.4.4).

2065-9001-202 / 0613 93
4 Installation - Maintenance - Repair
4.1 Installation of the separator ................................................................... 94

4.1.3 Motor ...................................................................................................... 97
4.1.4 Direction of rotation of the bowl ........................................................... 100
4.1.5 Speed and starting time of the bowl .................................................... 101
4.2 Fitting orifice plates, flow indicator, pressure transmitter .................... 103
4.2.1 Installing the orifice plates ................................................................... 104
4.3 Maintenance and lubrication ................................................................ 105
4.3.1 Maintenance schedule ......................................................................... 105
4.3.2 Hoses and hose pipes ......................................................................... 113
4.3.3 Lubrication ........................................................................................... 114
4.3.4 Lubrication Chart ................................................................................. 116
4.3.5 Table of lubricating oils ........................................................................ 118
4.3.6 Comments on table of lubricating oils for separators from
GEA Westfalia Separator Group ......................................................... 119
4.4 Bowl ..................................................................................................... 120
4.4.1 Dismantling the bowl ............................................................................ 122
4.4.2 Cleaning the bowl ................................................................................ 138
4.4.3 Cleaning the frame .............................................................................. 139
4.4.4 Cleaning the strainer and the operating water feeding system ........... 139
4.4.5 Cleaning the motor .............................................................................. 140
4.4.6 Important instructions for assembling the bowl ................................... 141
4.4.7 Assembling the bowl ............................................................................ 143
4.4.8 Replacing the polyamide gasket (bowl top) ........................................ 157
4.4.9 Replacing the polyamide gasket (annular piston)................................ 159
4.4.10 Reworking the sliding piston ................................................................ 166
4.5 Closing the hood .................................................................................. 167
4.6 Drive ..................................................................................................... 170
4.6.1 Important instructions for fitting and removing the drive ...................... 172
4.6.2 Removing the drive belt and spindle assembly ................................... 174
4.6.3 Dismantling the spindle assembly ....................................................... 178
4.6.4 Dismantling the centrifugal clutch ........................................................ 180
4.6.5 Fitting the spindle assembly ................................................................ 184
4.6.6 Fitting the centrifugal clutch ................................................................. 187
4.6.7 Fitting the motor ................................................................................... 193
4.7 Height adjustment ................................................................................ 198
4.7.1 Bowl height .......................................................................................... 198
4.7.2 Centripetal pump clearance ................................................................. 199
4.8 Final checks after assembling the separator ....................................... 201
4.9 Before a long-term shut-down of the separator ................................... 201
4.9.1 Preserving the separator ..................................................................... 201
4.9.2 Preserving the motor ........................................................................... 202
4.10 Storage ................................................................................................ 203
4.10.1 After delivery ........................................................................................ 203
4.10.2 Separator ............................................................................................. 203
4.10.3 Control system ..................................................................................... 204
4.11 Before restarting .................................................................................. 204
4.12 Disposal ............................................................................................... 205
4.12.1 Gear and lubricating oils ...................................................................... 205
4.12.2 Cleaning fluids ..................................................................................... 206
4.12.3 Separator ............................................................................................. 206

94 2065-9001-202 / 0613
4.1 Installation of the separator

• Refer to the project-specific dimensioned drawing.
• Pay attention to the installation guidelines.
4.1.1 Transporting the separator
CAUTION Use appropriate hoists to prevent accidents!

– Be sure to use suitably rated, intact hoists for transport and installation.
CAUTION Danger to life from hoists!

– Do not walk under suspended loads.
CAUTION Avoid accidents by using undamaged, complete tools!

• Use tools only for their intended purpose!
– For special tools, see Sections 2.9, 2.9.1 and 2.9.2.
– For standard tools, see Section 2.8.
• Always transport the separator without installed bowl!
• Unscrew the screw plug 1 from the

lower part of the frame.
Fig. 93

in the frame.
Fig. 94

2065-9001-202 / 0613 95
CAUTION Do not use the horizontal-

ly screwed-in eye bolts of the motor
to suspend the separator.
ATTENTION Do not damage any ma-

chine attachment parts when fastening
the ropes.
• Hang the transport ropes

– round the machine A,
– around the double nipple and
ATTENTION Prevent the ropes from

slipping!
• Wind one piece of rope twice round
the hook (see detail).

down gently.
Fig. 95
After transporting the separator:
• Remove hoist and ropes.

• Unscrew double nipple 1.
Fig. 96

96 2065-9001-202 / 0613
• Screw in screw plug 1.
Fig. 97
4.1.2 Installing the separator

• Before installing the separator make sure that
– sufficient space is available for operating and dismantling the machine.
– the foundation is not connected to foundations of other vibrating units to
avoid the transfer of vibrations.
• Align separator 1 with feet 2 and

plates 3 on foundation 4.
• Tack plates 3.
• Unscrew screws 5.
• Lift separator with feet (see sec-
tion 4.1.1).
• Weld plates 3 to foundation 4.
• Place the separator on plates 3 and
• Screw tight hex head screws 6.
Fig. 98

2065-9001-202 / 0613 97
4.1.3 Motor
Fig. 99 Start-up diagram (current and speed characteristics) – example
at
De- Enclo-
50 Hz 60 Hz 50 Hz 60 Hz
sign sure *
rpm min s kW rpm rpm
IP 55
see name- approx. 2 – IM V ISO-

3 4 4.8 3 000 3 600
plate 4 1 class
F*
* WS standard
The separator is driven by a three-phase AC motor via a centrifugal clutch and
the drive belt.
The specified motor ratings are minimum values which are based on the in-
creased starting current. Since the current consumption of the motor drops after
start-up, overloading of the motor during operation is not possible.
The starting time depends on the
– flywheel effect of the bowl,
– number of clutch shoes used,
– condition of the clutch shoes.
The starting current can peak at about 1.8 - 2 times the rated current (see start-
up diagram). This is to be considered when selecting switches, lead-in wires
and fuses.
The motor
– can be started direct online (WS standard) or via a motor control for star-
delta switching (Ex-zone).

98 2065-9001-202 / 0613
– is protected against overheating by thermal overload releases or a PTC

thermistor as sole protection.
(As WS standard, the motor is protected against overheating by three PTC
thermistors).
– can be equipped with a frequency converter if requested by the customer.
When using thermal overload releases, the motor has to be protected as fol-
lows:
– during operation by a release set to the rated current and
– during start-up by a second release set to 1.8 - 2 times the rated current.
The release set to the rated current must be bridged during start-up.
Note:
• The temperature feelers must be connected to a commercial tripping device.
• External voltage higher than 2.5 volts must not be applied to the connection
terminals of the temperature feelers.
• When testing for continuity, use an ohmmeter and not a test lamp.
Electrical connection
CAUTION: Danger to life and limb through electric current!

There might be residual voltage!
In the case of motors with space heaters, residual voltages in the motor
terminal box are possible despite switched off main switch.
Prior to working on the motor:

• Refer to the motor nameplate.
• Refer to the motor instruction manual.
• Refer to the frequency converter manual (if applicable).
Germany in accordance with the rules and regulations of the VDE (Verband
Deutscher Elektrotechnik/ Association of German Electrical Engineering) or of
the local electric power company.
• Any work on the motor may be carried out by an authorised electrician only.
• Connect the motor.

Refer to the motor instruction manu-
al.
Fig. 100 Connection schematic
The terminal board in the terminal box can be connected in star or delta.
• Check correct switching of the motor (star or delta).
Refer to the motor instruction manual.

2065-9001-202 / 0613 99
Star switching (example)
Fig. 101
Delta switching (example)
Fig. 102
ATTENTION:
• In the case of additional electrical components, PTC thermistors or space
heaters, refer to the motor manual.
Shipboard operation
• When operating the machine on board of ship, pay attention to the installation
guidelines issued by the respective classification societies.
• When using ship wiring cables, cable entry must be by means of marine-type
glands.

100 2065-9001-202 / 0613
4.1.4 Direction of rotation of the bowl
Provided that:
– The drive chamber is filled with oil
up to the half way mark on the sight
glass.
• Switch on motor.
Fig. 103
The bowl must rotate in clockwise direction when looked at from above.
The direction of rotation of the bowl is

correct when the drive belt rotates
clockwise (check through the sight
glass in the frame).
When the direction of rotation is incor-
rect the motor connections must be
reversed by an authorised specialist.
Fig. 104

operation:
CAUTION: Danger to life and limb

through electric current!
There might be residual voltage!
• Before working on the motor, note
that residual voltage may be pre-
sent!
• In this connection:
– Read the documentation supplied
by the frequency converter manu-
Fig. 105 facturer.
– Have protective measures imple-
mented by suitably qualified per-
sonnel.

2065-9001-202 / 0613 101
4.1.5 Speed and starting time of the bowl
Speed see name-plate

– for densities of the product up to
3
max. 0.991 kg/dm and
– for densities of the separated solids up to max.
3
1.4 kg/dm
Starting time approx. 2 – 4 min
The bowl speed has been rated so as to ensure the operating safety of the sep-
arator.
Before the first start-up

• Check spindle speed (= bowl speed)
with a hand tachometer before fitting
the bowl.
CAUTION!
Risk of injury through rotating
spindle.
• Keep a safe distance away from the
rotating spindle.
• Do not wear long, open hair or wide,
loose clothing!
• Wear a hairnet!
• IMPORTANT: Do not exceed the

maximum spindle running time of
1 minute!
• Speed deviations of up to 5 % are

permissible.
Fig. 106

102 2065-9001-202 / 0613
In case of frequency converter operation:

The frequency converter is equipped with a reliable frequency limitation to pre-
vent operation at inadmissibly high bowl speeds.
CAUTION!
• Operate the separator with fre-
quency converter, speed monitor-
ing device and hardware-
controlled speed shut-off device.
manipulate the frequency con-
verter to exceed the permissible
bowl speed (see nameplate)!
• Check from time to time that
– the bowl speed (see nameplate)
and
Fig. 107 – motor frequency (see nameplate
and frequency converter display!)
coincide with the separator speed.

2065-9001-202 / 0613 103
4.2 Fitting orifice plates, flow indicator, pressure transmitter

A set of orifice plates (with different inner diameters) and a set of commissioning
parts are supplied with the separator.
– The set of orifice plates is fastened to the separator hood.
– The set of commissioning parts comprises the flow indicator 4 or the pres-
sure transmitter 5.
By installing an orifice plate the separator throughput can be monitored.
Fig. 108
A Product feed line

B Product discharge line
1 Pressure gauge
2 Orifice plate
3 Orifice plate
4 Flow indicator (option – for control D10)
5 Pressure transmitter (option – for control E40)
6 3/2-way valve
ATTENTION! Before starting up the separator check that the following

parts are installed:
Orifice plates 2 and 3

• Select the orifice plates from the set of plates supplied, according to the re-
quired throughput capacity (see section 2.7).
• Install orifice plate 3 in product feed line A (see chapter 4.2.1).
• Install orifice plate 2 in product feed line B (see chapter 4.2.1).
Flow indicator 4 (option – for control D10)

• Remove the plug from the corresponding hole of 3/2-way valve 6.
• Secure the thread of flowmeter 4 with Loctite 245.
• Install flowmeter 4 into 3/2-way valve 6.

104 2065-9001-202 / 0613
Pressure transmitter 5 (option – for control E40)

• Remove the plug from the corresponding hole of 3/2-way valve 6.
• Fit pressure transmitter 5 in the 3/2-way valve 6 and connect to the control
unit in accordance with the order-specific circuit diagram. The circuit diagram
is kept inside the control cabinet.
4.2.1 Installing the orifice plates

Installation of the orifice plates is explained here for product feed line B for ex-
ample.
Required material:
– Open ended wrench
– Lubricating grease
• Unscrew corrugated hose 3.

• Insert the selected orifice plate 2 into
connection piece 1 and press in
evenly, by hand.
Fig. 109
• Slightly grease the threaded area of

connection piece 1
• Insert corrugated hose 3 and firmly
tighten with hexagon nut 2.
Fig. 110

2065-9001-202 / 0613 105
4.3 Maintenance and lubrication
• Special care must be taken when performing maintenance and lubrication

work.
Conscientiously performed maintenance and lubrication operations improve
the service life of the separator.
• In the case of accessories (motor, product pump, preheater, solenoid valve
block, etc.) the manufacturer’s maintenance and lubrication instructions must
be observed.
• Maintenance and repair work may only be carried out by persons
– who provide evidence of familiarity with the state of the art as a result of
briefings and training.
– who are adequately qualified for performing the work and for checking it if
required.
• Electrical work may only be carried out by an authorised electrician!
• Use only genuine spare parts from GEA Westfalia Separator Group.
The genuine spare parts are listed in the spare parts catalog.
4.3.1 Maintenance schedule
ATTENTION !
The following maintenance intervals are recommendations which apply only for normal operating
conditions.
Negative operating conditions (e.g. low-grade fuel, excessively high temperature, strong vibrations,
frequent starting and stopping of the separator, etc.) can necessitate shorter maintenance intervals.
To assure correct functioning and operating safety,

• in case of non-routine shut-down, see section 3.7 - manual operation.
• Pay attention to the following points during servicing:
– Oil level – Current consumption
– Temperatures – Starting time
– Pressures – Hose and hose pipes (see 4.3.2)
– Leakage – Pipe joints (e.g. flange or screwed connections, pipe clips)
– Vibrations
• Before assembling, grease the contact and guide surfaces of the main bowl components (see section 4.3.4 – lubrication
schedule).
• in the case of frequent starting and stopping of the separator, shaft-driven alternator operation and in power plants, the
condition of the clutch shoes must be checked more often than stated in this schedule. It is not possible to state a defini-
tive interval. We recommend checking the clutch shoes after 1000 operating hours or after 2 months at the latest.
• we recommend to have the separator checked by a WS serviceman once a year.

106 2065-9001-202 / 0613
Fig. 111 Set of spare parts "bowl/hood“ (operation: 1 year or 8,000 hours)

2065-9001-202 / 0613 107
Date of commissioning:
(to be filled in by user)
Maintenance work Remark

– After 4,000 operating hours – after 6 months at the latest
– After 12,000 operating hours – after 1 ½ years at the latest
Standard tools, • Check tools for visible damage.
Special tools
Bowl overhaul • Disassemble bowl and centripetal pump.
• Clean the bowl and centripetal pump parts and check for
corrosion and erosion.
• Clean all holes, nozzles and chambers of the hydraulic
system.
• The cones of bowl and spindle must be clean and dry
when fitting.
Replace gaskets. • Use set of spare parts: "bowl/hood“
(Operation: 1 year or 8,000 hours).
– See the adjacent figure.
Important: time-consuming installation!
Change polyamide gasket 100 only when it is damaged (see
section 4.4.9)!
Check the motor. • See instructions provided by the motor manufacturer.
Re-lubricate motor bearings (if required).
When using mineral oil: • See section 4.3.3 – Oil quality and oil change.
Change oil and thoroughly clean the drive chamber.
Clean the strainer and pipe in the operating liquid feed • See section 4.4.4.
system on the self-cleaning separator.
Carefully clean the holes in the non-return valve in the • See section 4.5.
water feed and rinse with water.
Check the functionality of the non-rerun valve.
Carefully clean the water detector (if provided) with a soft
cloth, use diesel oil if necessary.
Check the pressure gauge(es) for damage, display and
functionality.
Clean the sight glass(es) in the frame for observing the
drive belt.
Check the hoses and hose pipes and replace when neces-
sary.
Clean the filter in the suction line of the product feed pump
(option).

108 2065-9001-202 / 0613
Fig. 113 Set of spare parts “drive” (operation: 1 year or 8000 hours)

2065-9001-202 / 0613 109

– After 8,000 operating hours – after 1 year at the latest
– After 24,000 operating hours – after 3 years at the latest
Special tools • Have the load-carrying equipment checked by a compe-
tent person.
system.
when fitting.
Replace gaskets and piston guide ring. • Use set of spare parts: "bowl/hood“
section 4.4.9)!
Clean the inside of the upper section of the frame. • Remove bowl.
Replace gaskets. • Use set of spare parts: "drive"
Replace the drive belt. (Operation: 1 year or 8,000 hours).
Replace spindle roller bearings. – See the adjacent figure.
Replace vibration absorber.
Check grooved ball bearings of centrifugal clutch and re- • Use set of spare parts: "drive"
place if necessary. (Operation: 2 years or 16,000 hours).
Check thickness of clutch shoes (1), and replace , when – See Fig. 115.
h smaller than 18 mm.
Clutch shoe when new: h = 26 mm
Change oil and thoroughly clean the drive chamber. When using mineral oil (2)
When using synthetic oil (2)
Check the bowl height. • See section 4.7.1.
In case of direct current: • Check after motor or drive replacement only.
Check the spindle speed (bowl). • See section 4.1.5.
Check the starting time. • See section 4.1.5.
Clean the strainer and pipe in the operating liquid feed • see section 4.4.4.
water feed and rinse with water.
drive belt.
sary.
Check that vibration absorbers are fully functional (option).
(option).
(1) Shorter maintenance intervals are required if the separator is frequently started and stopped, operated by a shaft-driven alternator or
installed in a power plant. It is not possible to state a definitive interval. We recommend checking the clutch shoes after 1,000 operat-
ing hours or after 2 months at the latest.
(2) See section 4.3.3 – Oil quality and oil change

110 2065-9001-202 / 0613
Fig. 115 Set of spare parts “drive” (operation: 2 years or 16,000 hours)

2065-9001-202 / 0613 111

Special tools • Have the load-carrying equipment checked by a compe-
tent person.
system.
when fitting.
Replace gaskets, piston guide ring and guide strips. • Use set of spare parts: "bowl/hood“
section 4.4.9)!
Clean the inside of the upper section of the frame. • Remove bowl.
Replace gaskets. • Use set of spare parts: "drive"
Replace the drive belt. (Operation: 2 years or 16,000 hours).
Replace spindle roller bearings. – See the adjacent figure.
Replace vibration absorber.
Replace grooved ball bearings of centrifugal clutch.
Check thickness of clutch shoes (1), and replace , when
h smaller than 18 mm.
Clutch shoe when new: h = 26 mm
Change oil and thoroughly clean the drive chamber. When using mineral oil (2)
When using synthetic oil (2)
Check the bowl height. • See section 4.7.1.
In case of direct current: • Check after motor or drive replacement only.
In case of three-phase current: • Check only after drive replacement.
Check the starting time. • See section 4.1.5.
Clean the strainer and pipe in the operating liquid feed • see section 4.4.4
operating water feed.
drive belt.
sary.
Check that vibration absorbers are fully functional (option).
(option).
(1) Shorter maintenance intervals are required if the separator is frequently started and stopped, operated by a shaft-driven alternator or
installed in a power plant. It is not possible to state a definitive interval. We recommend checking the clutch shoes after 1,000 operat-
ing hours or after 2 months at the latest.
(2) See section 4.3.3 – Oil quality and oil change

112 2065-9001-202 / 0613
Maintenance work
– After 48 000 operating hours – after 6 years at the latest
• Equip the separator with new vibration isolators (e.g. rubber-metal cushions beneath the machine feet).
• Have the separator inspected by a service specialist from GEA Westfalia Separator Group.

2065-9001-202 / 0613 113
4.3.2 Hoses and hose pipes

Replace hose pipes when an inspection reveals one or more of the following de-
fects:
• Damage of the outer layer down to the fabric (e. g. chafe marks, cuts or
cracks).
• Leaky spots.
• Damage to or deformation of the hose fittings.
– Slight surface damage is not a reason for replacement.
• The hose becomes dislodged from the fitting.
• Corrosion of the fitting diminishing function and strength.
Insulating plastic tube for cable
NOTICE: Avoid abrasion!

• Fit the insulating plastic tube (1)
along the entire length of the cable
tree (contact points to the machine).
• Adapt the length of the insulating
plastic tube (1).
Fig. 116
Corrugated hose with braiding
NOTICE: Do not twist the corrugat-

ed hose!
• Fit the corrugated hose torsion-free.
Fig. 117

114 2065-9001-202 / 0613
4.3.3 Lubrication
The spindle bearings are splash-lubricated from a central oil bath.
MOTOR BEARINGS
For re-greasing the motor bearings, refer to the instructions of the motor manu-
facturer.
OIL QUALITY (mineral oil)

The mineral gear oil tested by GEA Westfalia Separator with the designation
"Separator lube oil CLP 100" meets the requirements and should preferably
be used.
Designation
according to DIN 51502 CLP
100
Designation as per ISO 3498 CC 100
Viscosity class SAE 30
o o 2
Viscosity (at 40 C/104 F) 100 ± 10 mm /s (cSt)
Part Number 0015-0003-080 (2.5 litres)
Dispose of the oil as per instructions of the oil manufacturer.
The viscosity class SAE 30 covers a larger viscosity range than specified here.
However, only oils with the viscosity range specified here may be used.
OIL QUALITY (synthetic oil)

Use the synthetic lube oil tested by GEA Westfalia Separator!
Viscosity class (ISO) VG 68

Viscosity
o o 2
– at 40 C (104 F) 65 mm /s
o o 2
– at 100 C (212 F) 10,4 mm /s
Viscosity index (VI) 147
o o
Density (at 15 C/59 F) 0.857 g/ml
based on Polyalphaolefin
Part Number 0015-0020-010 (1 litre)
Dispose of the oil as per instructions of the oil manufacturer.

2065-9001-202 / 0613 115
OIL QUANTITY
IMPORTANT: Do not forget to top up the oil in good time!
Filling in oil
Fill the drive with oil before commis-
sioning the separator.
• Unscrew the screw plug and
• fill in oil through the charge hole.
Filling quantity approx. 2.5 litres
Fig. 118
Oil level
IMPORTANT:
• Check the oil level only when the
separator is at standstill.
• The oil level must never drop below
the lower third of the sight glass dur-
ing operation.
1 Maximum oil level

2 Minimum oil level
Fig. 119
Minimum oil level approx. up to lower third of sight glass

(at separator standstill)
Maximum oil level up to middle of sight glass
(at separator standstill)
OIL CHECK
• Check the oil level every week!
• From time to time undo the oil drain screw and check whether there is water
in the oil bath. When the oil exhibits a milky colouring (emulsification), the oil
must be changed immediately.
OIL CHANGE
• Change oil after about
– 4000 operating hours or 6 months at the latest (mineral oil).
– 8000 operating hours or 1 year at the latest (synthetic oil).
• Clean sight glass.

116 2065-9001-202 / 0613
4.3.4 Lubrication Chart
Fig. 120 Lubrication schedule

2065-9001-202 / 0613 117
Lubricant Lubrication frequency

Lubricat- Amount of
after Lubrication point
ing point lubricant
Designation Marking operating per year
hours
CLP
100
Lubricating oil DIN 51502 3

4 000 2x 2 500 cm Drive chamber
(mineral)
1
CC 100
ISO 3498
Lubricating oil Mobil SHC 626 3

8 000 1x 2 500 cm Drive chamber
(synthetic) ISO VG 68
2 according to instructions of motor manufacturer Motor bearings
Gaskets, threads and

sliding surfaces of the
3 2x
bowl and the centripetal
pump
Lubricating see
as required apply sparingly
4 grease parts list 1x Threads of fittings
- Threads of tools
• Check oil level regularly through sight glass.

• Manual lubrication
• Refer to lubricating oil table in section 4.3.5!

118 2065-9001-202 / 0613
4.3.5 Table of lubricating oils
Lubricating oil types suggested by selected companies

Viscosity
Westfalia Separator Group Manufac- at 40 °C (104 °F)
Designation
turer 2
mm /s (cSt)
Lubricating oil table BLASIA 100
for separators operating onshore and on-board ships
RADULA 100 100
DIESEL GAMMA 30
Separator Lubricating oil
ATLANTA MARINE 30
Viscosity 105
DISOLA M 3015
(Designation to DIN
MONTANOL HK 100 100

Oil filling
Kinematic
Symbol
51502)
viscosity ENERGOL GR-XP 100 100

Type
at 40 °C ENERGOL DL-MP 30 114
(104 °F)
2
mm /s HYSPIN AWS 100
l
(cSt) 100
…SE 5 ALPHA ZN 100
MARINE HEAVY 99
GST OIL 100

100
NL Gear Compound 100
1
Veritas Marine Oil R&O 30 108
DELO 3000 Marine Oil 30 104
ATLANTA MARINE 30
105
DISOLA M 3015
…SE 10 TURBINE T 100 95
EXX-MAR XP 110
…SC 18 NUTO H 100
100
SPARTAN EP 100
2,5
…DA 20 GULF HARMONY 100 95
…SE 20 VERITAS 30 110
CLP 90 to 110 0015-0003-080 HIDRAOIL HD 70 95

…SC 40 100 (2.5 l)
…SE 40
MOBILGARD 312 106
…SE 50 GADINIA 30 104

3,7
ROTELLA MX SAE 30 105
HYDRA WAY HMA 100

100
LOAD WAY EP 100
…SC 60
DORO AR SAE 30 119

…SD 70 TARO XD SAE 30 105
…SE 70
5,0
…DA 80
…SC 80
…SE 80

2065-9001-202 / 0613 119
4.3.6 Comments on table of lubricating oils for separators from GEA Westfalia Separator Group
Faultless functioning of separators very much depends on the proper type of lubricating oil used, since a
high grade oil, selected to meet all service requirements, will minimize the wear, thus extending the ser-
vice life and increasing the operating safety.
For the lubrication of our separators we recommend using the oils specified under "GEA Westfalia Sepa-
rator Group" since they are subjected to continuous quality checks. Oils proposed from some firms are
not subjected to these tests.
Therefore, GEA Westfalia Separator Group cannot give a performance guarantee for those oils.
Be sure to select only high grade solvent refined products.
The specified oil types meet the requirements according to DIN. Under unfavourable operating condi-
tions, e.g. high temperatures, the quality of the oils may be insufficient so that more efficient oils, e.g.
synthetic oils, must be used. If necessary, consult GEA Westfalia Separator Group.
For the different separator types and oil types the viscosity ranges are specified in the table of lubricating
oils.
o o
The separator working temperature is normally above 80 C (176 F). At those temperatures some oils
age quickly, so that they have to be changed prematurely.
Be sure not to use lubricating oils with viscosities lower than those specified in the table. Due to the pos-
sibility of the oil film breaking down, oil of too low a viscosity will give insufficient lubrication, resulting in
increased wear. However, oils with a slightly higher viscosity than specified may be used.
Please note that the viscosity classes SAE 30, 40 and 50 (SAE = Society of Automotive Engineers) cover
large viscosity ranges. However, the lower limits for the viscosity ranges defined for the individual separa-
tor types may not be undershot.

120 2065-9001-202 / 0613
4.4 Bowl
Fig. 121 Exploded view of bowl and centripetal pump

2065-9001-202 / 0613 121
Pos. Designation Dimensions
20 (1) Bowl bottom, compl.

30 Gasket
40 Piston guide ring
50 (2) Water chamber bottom
60 Gasket
70 Gasket
80 Allen screw ISO 4762 – M 8 x 16 – A4-80
90 Annular piston
100 Gasket
110 Gasket
120 Closing chamber bottom
130 Gasket
140 Gasket
150 Gasket
180 Sliding piston
200 Gasket
210 (1) Distributor
220 Disk stack, complete

230 Separating disk
240 (1) Bowl top
250 Gasket
260 Gasket
290 Threaded pin ISO 4026 - M 10 x 10 -1.4571
310 Gasket
320 Centripetal pump chamber
cover
330 Centripetal pump chamber
cover
340 Lock ring
350 Spindle screw
360 Gasket
370 Regulating ring
510 Centripetal pump, compl.

520 Gasket
530 Sensing liquid pump
540 Gasket
550 Spacer ring
560 Gasket
570 Gasket
(1) IMPORTANT: This part can only be replaced by a WS service specialist!

The complete bowl must be re-balanced in one of our authorized workshops or in the manufacturer’s plant.
(2) IMPORTANT: This part can only be replaced by a WS service specialist!
A vibration check must be carried out on the machine by a WS service specialist.

122 2065-9001-202 / 0613
4.4.1 Dismantling the bowl

• Switch off the main switch and lock it to prevent it being switched back on.
CAUTION Danger to life from separator parts rotating at high speed!

still.
Standstill of the drive belt

• Shine a torch through the sight glass
in the frame,
• carry out a visual check to ensure
that the drive belt is no longer mov-
ing.
Fig. 122
If the sight glass in the frame is not clear:

CAUTION Danger of injury from rotating drive belt!
• Only carry out a visual check to ensure that the drive belt is no longer moving.
– Do not touch the drive belt through the sight glass opening in the frame!

If a drive belt is torn, defective or has come off:
still.
• Be sure to observe the stopping time of 90 minutes until dismantling the
separator!
CAUTION Danger of injury from very hot separator parts!

When carrying out maintenance work, there is a danger of injury from hot sepa-
o
rator parts (separating temperatures of 70 to 100 C (158 – 212 °F)).

2065-9001-202 / 0613 123
CAUTION Danger to life and limb from electric current!

Potential residual voltage!
terminal box are possible even if the main switch is off!

• Refer to the motor instruction manual.
• Refer to the frequency converter manual (option).
the local electric power company).
• Any work on the motor may be carried out only by an authorised electri-
cian!
• Remove the bowl from the frame only in accordance with this section.
• Avoid damaging bowl parts when fitting and removing them through
– Accurate positioning
– No inclined hoisting!
– Select the low lifting speed of the hoist.

• Use suitably rated, intact hoists.
CAUTION Danger to life when transporting heavy parts!

• Do not walk under suspended loads.

• Do not use force when removing or fitting parts.
• Handle all bowl parts gently and always set them down on a rubber mat or a
wooden pallet.
CAUTION Danger of imbalance!

If an installation is equipped with several separators:
• Do not interchange parts from different bowls.
The bowl parts are marked with the machine no. or the last three digits of the
machine no.

124 2065-9001-202 / 0613
CAUTION
• Certain bowl parts (see Sec-
tion 4.4) may be pre-assembled
and balanced only by specialists
from GEA Westfalia Separator
Group or in workshops author-
ised by GEA Westfalia Separator
Group.
Unqualified balancing can lead to
dangerous operating states (vi-
brations) and destruction of the
separator with danger to life and
limb.
Fig. 123
Hinging up the hood
• Unscrew filling and displacement

water line 1.
Fig. 124
• Unscrew handle connection piece 1

by lightly hammering with a mallet
(left-hand thread); at the same time
• hold the centripetal pump with offset
screwdriver 2.
Fig. 125

2065-9001-202 / 0613 125
• Remove handle connection piece 1.
Fig. 126
• Unscrew three hex head screws with

their washers.
Fig. 127
• Hinge up the hood.
CAUTION: Danger of injury by in-

correct hinging up of the hood!
• The stirrup must register properly.
Fig. 128
If necessary (see section 4.3.1):

• Take gasket 1 out of the upper sec-
tion of the frame.
Fig. 129

126 2065-9001-202 / 0613
Removing the centripetal pump
Required special tool

– Double hook wrench
• Loosen the centripetal pump cham-

ber lock ring using the double hook
wrench (left-hand thread) and re-
move it.
Fig. 130
• Screw handle connection piece into

the centripetal pump (left-hand
thread).
• Remove the complete centripetal
pump together with the centripetal
pump chamber covers.
Fig. 131

– Pressure piece 1
• Insert pressure piece 1 into spacer

ring 2.
• Pull off spacer ring 2 with fitted gas-
kets with the aid of a commercial
puller.
Fig. 132

2065-9001-202 / 0613 127
• Remove the following parts if nec-

essary::
– centripetal pump chamber cover 1
with inserted gasket,
– sensing liquid pump 2 with insert-
ed gaskets,
– regulating ring 3,
– centripetal pump chamber cover 5
with gaskets 4 and 6,
– centripetal pump 7 with inserted
gasket.
Fig. 133
Lifting out the bowl
Required special tool:

– Socket wrench 1
• Unscrew the spindle screw (with

inserted gasket) with socket wrench
1 and a commercially available
ratchet wrench (left-hand thread)
and remove it.
Fig. 134

– Eye bolt 1
Eye bolt 1 comprises ring nut, hexagon
nuts and bolt.
CAUTION: Avoid accidents by using

undamaged and complete tools!
– The ring nut and the upper hexagon
nut must always be screwed into the
bolt and be secured with high-
strength fluid sealant, e.g. Loctite
275.
Fig. 135

128 2065-9001-202 / 0613
• Unscrew hexagon nut 2.

• Screw the eye bolt 1 into the bowl
bottom.
• Force the bowl off the spindle cone
by at least 10 mm.
Fig. 136
CAUTION: Danger to life when

transporting heavy parts!
– Never step under suspended loads.
• Lift the bowl out of the frame by
means of the hoist.
• Place the bowl on a rubber mat or
wooden pallet for further disman-
tling.
Fig. 137
Compressing the disk stack
Required special tools

Compressing device:
– Eye bolt 1
– Bell-shaped piece 3
• Grease the bearing surface of bell-

shaped piece 3 (see section 4.3.4).
• Mount bell-shaped piece 3 on the
bowl top.
• Screw eye bolt 1 into the bowl bot-
tom.
Fig. 138

2065-9001-202 / 0613 129
• Compress the disk stack firmly.

– Firmly tighten hexagon nut 1.
Fig. 139
Lift off the bowl top.
• Unscrew three threaded pins out of

the bowl top with a screwdriver.
Fig. 140

– Complete ring spanner 1
• Remove three hexagon nuts 3 from

hex head screws 2.
Fig. 141

130 2065-9001-202 / 0613
Important:
The "O" marks of the bowl top and of
the bowl bottom must be visible.
– Do not hide it by the ring spanner 1!
• The arrow and the “open” label of

the ring spanner 1 must face up-
wards.
Fig. 142
• Screw spanner wrench 1 to the bowl top.

– The bushes of ring spanner 1 must engage in the bores of the bowl top.
– Screw in three hex head screws 2 of the ring spanner and firmly tighten.
CAUTION: The rotating lever may

cause injury!
– Be sure to work carefully in the area
around the lever.
• Loosen the bowl top with a striker

(left-hand thread) and unscrew it.
• Remove eye bolt, bell-shaped piece

and spanner wrench.
Fig. 143
• Lift off the bowl top with fitted gas-

kets by hand.
Fig. 144

2065-9001-202 / 0613 131
Removing the separating disk
• Remove the separating disk from

the distributor neck.
Fig. 145
Removing the disk stack and the distributor
• Remove the disks from the distribu-

tor, one by one or in groups.
Fig. 146
• Remove the distributor.
Fig. 147

132 2065-9001-202 / 0613
Removing the sliding piston
• Insert the spindle screw into the hub.
Fig. 148

– Eye bolt 1
• Unscrew hexagon nut 3
Fig. 149
• Assemble eye bolt 1 and bell-

shaped piece 2:
– Screw eye bolt 1 into bell-shaped
piece 2
– Screw eye bolt 1 into hexagon nut
3 by approx. 20 mm.
Fig. 150

2065-9001-202 / 0613 133
• Grease the thread of sliding piston 1

(see chapter 4.3.4).
• Screw the bell-shaped piece with
fitted eye bolt into the thread of the
sliding piston.
Fig. 151

– Socket wrench 1
• Press off the sliding piston from the

bowl bottom by turning the socket
wrench clockwise.
Fig. 152
• Remove the sliding piston (with fitted

gasket) with bell-shaped piece and
eye bolt.
• Remove the bell-shaped piece and
the eye bolt.
Fig. 153

134 2065-9001-202 / 0613
Removing the annular piston and the closing chamber bottom

– Socket wrench 1
• Unscrew the Allen screws holding

the bowl bottom and the closing-
chamber bottom together.
Fig. 154

– Eye bolt 1
– Assembling device 3
• Unscrew hexagon nut 4
Fig. 155

shaped piece 2:
piece 2
– Screw eye bolts 1 into hexagon
nut 3 by approx. 20 mm.
Fig. 156

2065-9001-202 / 0613 135
• Place the bell-shaped piece with

fitted eye bolt into the bowl bottom.
• Fit assembling device 3 onto the
bell-shaped piece.
• Loosen three Allen screws 4 using
the ratchet wrench (with extension
and socket).
• Slip three disks 5 of the assembling
device towards the periphery, under
the rim of annular piston 6.
• Make sure that disks 5 are properly
positioned in the mounting groove of
Fig. 157
the annular piston.
• Firmly re-tighten Allen screws 4.
• Force off closing chamber bottom 3

together with annular piston 4 by
turning wrench 5 clockwise.
Fig. 158
• Remove closing chamber bottom 3

and annular piston 4 (with fitted gas-
kets) with the bell-shaped piece and
the eye bolt.
the eye bolt.
Fig. 159
• Separate annular piston 1 from clos-

ing chamber bottom 2 by tapping
with a mallet – as illustrated.
Fig. 160

136 2065-9001-202 / 0613
• Unscrew spindle screw 1.
Fig. 161
If necessary:
• Remove gasket 1 and piston guide
ring 2.
Fig. 162

2065-9001-202 / 0613 137
Removing the water chamber bottom

– Socket wrench 1
• Turn bow bottom through 180 (up-

o
side down).
• Unscrew four Allen screws 2 from
water chamber bottom 3.
Fig. 163
• Force off water chamber bottom 1

with a screwdriver and remove it
with inserted gaskets.
Fig. 164

138 2065-9001-202 / 0613
4.4.2 Cleaning the bowl

It is generally not necessary to dismantle self-cleaning bowls for cleaning after
separation unless
– the nature of the product makes it necessary,
– the separator is to be shut down for a lengthy period (see section 4.9).
• Dismantle and clean the bowl for checking from time to time. See
tion 4.3.1 - Maintenance schedule.
• Use only a cleaning agent that is approved for the field of application!
• Do not use acid or chloric cleaning agents.

Chlorine attacks stainless steel parts.
• Dissolve dried scale with citric acid.
• For cleaning the individual disks and bowl parts

Do not use metal scrapers and metal brushes!
• Take the gaskets out of the bowl

parts.
• Clean the grooves and gaskets to
avoid corrosion in the grooves.
• Replace damaged, very swollen,
hardened or brittle gaskets immedi-
ately.
Fig. 165
• Clean the small holes for the feed and discharge of the operating liquid with
particular care to ensure trouble-free bowl ejections.
• Clean the distributor between the

ribs with the brush on the inside and
outside.
When the distributor neck is very
dirty, the feed clogs which can
cause overflow.
Fig. 166
• Apply a thin coat of grease to the guide surfaces and threads of the bowl
parts after drying (see 4.3.4 Lubrication schedule).
• Reassemble the bowl immediately after cleaning!

2065-9001-202 / 0613 139
4.4.3 Cleaning the frame
CAUTION: Danger to life through electrical components!

• Never rinse off the motor with a direct water jet.
• Use only a cleaning agent that is approved for the field of application!
ATTENTION!
• Do not use acid or chloric cleaning agents.
Chlorine attacks stainless steel parts.
• Dissolve dried scale with citric acid.
• Clean the inside of the upper section of the frame from time to time:
To do this:
– Refer to the maintenance schedule (section 4.3.1),
– dismantle the bowl (section 4.4.1).
ATTENTION: Escaping cleaning

liquid!
When the bowl has been removed, no
cleaning liquid must spill onto the
drive belt via the spindle.
• Make sure that protective cap 2 and
spindle cap 1 with inserted gasket
are installed.
Fig. 167
4.4.4 Cleaning the strainer and the operating water feeding system
• The strainer and the operating water feeding system must be cleaned de-
pending on the quality of the operating water and overall load. See
tion 4.3.1 Maintenance schedule
• Use citric acid in case of furring.
• Thoroughly clean the parts with water.
Replacing or cleaning the filter element
CAUTION: Danger due to electrical current!

• Switch off the main switch and lock it.
• Close the main valve for operating water, filling and displacement water.

o
separator parts (separating temperatures of 70 to 100 C (158 – 212 °F) ).

140 2065-9001-202 / 0613
• Undo screw 1 (jaw span 22) with

fitted gasket 2.
• Remove filter element 3.
• Clean or replace filter element 3.
– Use citric acid in case of furring.
– Thoroughly clean the parts with
water.
Fig. 168
• Fit the cleaned or new filter element 3.

IMPORTANT: Cooper strip to the inside!
• Firmly screw in screw 1 with fitted gasket 2 so that it seals well.
4.4.5 Cleaning the motor
CAUTION: Danger to life through electrical components!

• Never rinse off the motor with a direct water jet.
• Keep the motor clean as specified in the manual.

2065-9001-202 / 0613 141
4.4.6 Important instructions for assembling the bowl

If the bowl has not been correctly assembled or is inadequately cleaned, it is
possible for forces to be produced in the bowl when it rotates at high speed
which jeopardize the operating safety of the separator!
• Therefore, the cleaning instructions (section 4.4.2) and assembling instruc-
tions (section 4.4.7) must be followed exactly.
• Install the bowl in the frame only in accordance with section 4.4.7
The points below should also be noted:
ATTENTION!
• Before assembling the bowl, ensure that the guide and bearing surfaces of
the bowl parts are clean.
• Grease the guide surfaces as specified in the lubrication schedule (see 4.3.4).
• Some bowl parts have to be fitted in

fixed positions relative to one anoth-
er.
• Locking devices and alignment
marks must be in perfect condition.
ATTENTION
The bowl must not be operated un-
less this is the case!
Fig. 169
• When inserting the bowl parts, make

sure that the "O" marks on all parts
are aligned.
(Only then will the parts assume
their correct positions as determined
by locking pins and guide ribs).
Fig. 170
• Avoid damaging bowl parts when fitting and removing them through



142 2065-9001-202 / 0613
CAUTION: Avoid accidents by using undamaged, complete tools!


• If the installation has several separa-
tors, be sure not to interchange
parts of different bowls.
The parts are marked
– with the machine no. or
– the last three digits of the machine
no.
Fig. 171
• Thoroughly clean the gasket

grooves of the individual bowl parts
and apply a thin coat of grease.
• After fitting check that
– the gaskets are not twisted,
– the gaskets are evenly positioned
in the groove.
Fig. 172

2065-9001-202 / 0613 143
4.4.7 Assembling the bowl
• Pay particular attention to the “Safety” 4.4.2 and 4.4.6 sections.

• For dimensions of parts, see 4.4 – exploded view.
Installing the water chamber bottom

– Socket wrench 4
• Insert gaskets 1 and 2 in the

grooves of the water chamber bot-
tom.
• Turn bowl bottom through 180
o
(compared to fitting position).

• Place water chamber bottom 3 on
the bowl bottom.
• Check "O" marks of the bowl bottom
and the water chamber bottom.
– The "O" marks must be aligned.
• Tightly screw in the four cylinder
bolts 5 connecting the water cham-
ber bottom to the bowl bottom.
Torque: 25 Nm
Fig. 173
Fitting the annular piston
• Grease contact surfaces as speci-

fied in the lubrication schedule
(see 4.3.4).
• Insert gasket 1 and piston guide
ring 2 into the grooves of the bowl
bottom.
Fig. 174

144 2065-9001-202 / 0613
• For replacing the polyamide gasket

1, see section 4.4.9.
• Insert gasket 2 into the groove of the
annular piston, applying firm and
even pressure.
(see 4.3.4).
Fig. 175
• Insert annular piston 1 into bowl

bottom 2.
Fig. 176

Compressing device
– Eye bolt 1
Fig. 177
• Rotate sliding piston 3 through 180

o
(opposite the fitting position) and se-

cure.
• Place bell-shaped piece 2 on the
sliding piston.
• Screw eye bolt 1 into the bowl bot-
tom through the bell-shaped piece
and the sliding piston.
Fig. 178

2065-9001-202 / 0613 145
• Press the annular piston 1 into the

bowl bottom by turning hexagon nut
2 clockwise with the open-ended
wrench.
• Remove special tools and sliding

piston.
Fig. 179
Installing closing chamber bottom
• Insert gaskets 1, 2 and 3 in the

grooves of the closing chamber bot-
tom.
(see 4.3.4).
Fig. 180
• Insert closing chamber bottom 1 into

the annular piston.
• Check "O" marks of the closing
chamber bottom and the bowl bot-
tom.
Fig. 181

146 2065-9001-202 / 0613
Required standard tools:

– Two Allen screws 1 (M 8 x 20)
• Screw Allen screws 1 opposite into

the bowl bottom.
• Insert the closing chamber bottom 2
into the bowl bottom by turning the
Allen screws 1 clockwise.
• Unscrew Allen screws 1.
Fig. 182
• Fasten closing chamber bottom 1

onto the bowl bottom by tightening
all Allen screws 2 crosswise.
Fig. 183

– Socket wrench 1
• Firmly tighten the Allen screws

holding the closing chamber bottom
and the bowl bottom together.
Torque: 25 Nm
Fig. 184
• Make sure that piston guide ring 1

fits tightly in the groove.
Fig. 185

2065-9001-202 / 0613 147
Installing the sliding piston
• Insert gasket into the groove of the

sliding piston.
• Grease guide surfaces as specified
in the lubrication schedule
(see 4.3.4).
Fig. 186

Compressing device:
– Eye bolt 1
Fig. 187
Eye bolt 1 comprises ring nut, hexagon nuts and bolt.

CAUTION: Avoid accidents by using undamaged and complete tools!
– The ring nut and the upper hexagon nut must always be screwed into the bolt
and be secured with high-strength fluid sealant, e.g. Loctite 275.
• Grease thread 1 of the sliding piston

(see chapter 4.3.4).
• Screw bell-shaped piece 2 into the
thread of the sliding piston.
Fig. 188

148 2065-9001-202 / 0613
• Install the sliding piston (with fitted

gasket) and screwed-in bell-shaped
piece into the bowl bottom.
• Screw the eye bolt into the bowl
bottom through the bell-shaped
piece.
• Press the sliding piston into its seat
as far as it will go by turning hexa-
gon nut 1 clockwise with an open-
ended wrench.
the eye bolt.
Fig. 189
Installing the distributor and the disk stack
• Insert the distributor into the sliding

piston.
– Pay attention to correct position-
ing.
• Check "O" marks on the bowl bot-
tom and the distributor.
Fig. 190
ATTENTION: Ensure the total num-

ber of disks is correct!
This is marked on the blind disk, e.g.
84/1:
– Total number of disks A and B = 84
(number of disks with spacers
A + number of blind disks B)
– Number of blind disks B = 1
Fig. 191

2065-9001-202 / 0613 149
ATTENTION: The last disks must be

properly inserted into the guide ribs
of the distributor!
• Carefully stack the disks on the dis-

tributor neck, one by one or in
groups.
Fig. 192
Fitting the separating disk
• Mount the separating disk.

ing!
• Check "O" marks on the separating
disk and bowl bottom.
Fig. 193
• Lightly compress the disk stack with

the bell-shaped piece and the eye
bolt.
Fig. 194

150 2065-9001-202 / 0613
Installing the bowl top
• Thoroughly clean the grooves for

gaskets 1 and 2 in the bowl top.
• Check gaskets 1 and 2:
– Replace gaskets if damaged.
– Insert the gaskets.
• Check inserted gasket 3.
– Replace gasket if damaged.
– For replacing the polyamide gas-
ket 3 see section 4.4.8.
Fig. 195
ATTENTION: Prevent seizing of the

threads!
• The following items must be careful-
ly cleaned, wiped dry and greased in
accordance with the lubrication
schedule (see 4.3.4).
– threads and guide surfaces of
bowl bottom and bowl top
– bearing surfaces of bowl top and
sliding piston
Fig. 196

– Complete ring spanner 1
• Remove three hexagon nuts 3 from

hex head screws 2.
Important:
The "O" mark on the bowl top must be
visible.
– Do not hide it by the ring spanner 1!
• If threaded pins are screwed into the
bowl top, remove them with a
Fig. 197
screwdriver.
• The arrow and the “open” label of the ring spanner must face upwards.
• Screw spanner wrench 1 to the bowl top.
– The bushes of ring spanner 1 must engage in the bores of the bowl top.
– Screw in three hex head screws 2 of the ring spanner and firmly tighten.

2065-9001-202 / 0613 151
• Manually screw the bowl top into the

bowl bottom as far as possible (left-
hand thread).
Fig. 198
Compressing the disk stack
• Compress the disk stack firmly.

– Firmly tighten hexagon nut 1.
Fig. 199
• Compress the disk stack again and

simultaneously
• screw in the bowl top with ring
spanner 1 (left-hand thread).
Fig. 200

152 2065-9001-202 / 0613
CAUTION: The rotating lever may

cause injury!
– Be sure to work carefully in the area
around the lever.
CAUTION: A loose bowl top can

endanger life!
• Strike the bowl top with a striker until
the "O" mark is reached (left-hand
thread).
Fig. 201
• Check "O" marks on the bowl top and the bowl bottom.
• Detach the tools.
• Screw in three threaded pins using a

screwdriver.
Fig. 202
Installing the complete bowl and the centripetal pump
ATTENTION: Do not grease the con-

ical parts!
• Clean the spindle cone with a suita-

ble cloth.
– The cone must be clean and dry.
Fig. 203

2065-9001-202 / 0613 153

– Eye bolt 1

• Screw the eye bolt 1 into the bowl
bottom.
Fig. 204
• Turn bowl through 90 (opposite the

o
fitting position).
ATTENTION: Do not grease the

bowl hub!
• Clean the bowl hub with a suitable
cloth.
– The cone must be clean and dry.
Fig. 205

• Carefully place the bowl on the
spindle cone using eye bolt and
hoist.
• Undo the eye bolt from the bowl
bottom and remove the hoist.
Fig. 206

– Socket wrench
– Torque wrench
• Fit gasket 1 to spindle screw 2.

• Grease the thread of the spindle
screw (see section 4.3.4).
• Put spindle screw in socket wrench
and screw in (left-hand thread).
Fig. 207

154 2065-9001-202 / 0613
CAUTION: A loose spindle screw

can endanger life.
• Tighten the spindle screw.

Torque: 50 Nm
Fig. 208
• Check whether the spindle and bowl

are centric.
The reference dimension B
– is 3.5 ±1.5 mm
– between the bowl and the upper
• Note bowl height A (see sec-

tion 4.7.1).
Fig. 209
• Insert gasket 1 in the centripetal

pump groove.
• Lightly grease threads and contact
surfaces of the centripetal pump.
• Install centripetal pump 2.
Fig. 210
• Insert gaskets 1 and 2 in the

grooves of the centripetal pump
chamber cover.
• See section 2.3.
Fig. 211

2065-9001-202 / 0613 155

cover with fitted gaskets.
– The “O” marks of the centripetal
pump chamber cover and the
bowl top must be aligned.
Fig. 212
• Mount the regulating ring selected

from the set of regulating rings.
• See section 2.5.
Fig. 213
• Insert gaskets 1 and 2 in the sensing

liquid pump grooves.
• Grease guide surfaces.
• Install sensing liquid pump.
Fig. 214
• Insert gasket 1 in the groove in the

centripetal pump chamber cover.
Fig. 215

156 2065-9001-202 / 0613

cover.
– The “O” marks of the centripetal
pump chamber cover and the
bowl top must be aligned.
Fig. 216

– Double hook wrench
• Grease the threads on the bowl top

and on the centripetal pump cham-
ber lock ring as specified in the Lu-
brication schedule (see 4.3.4).
CAUTION:
A loose centripetal pump chamber
lock ring can endanger life!
• Screw tight the centripetal pump
chamber lock ring using the double
Fig. 217 hook wrench (left-hand thread).
• Insert gaskets 1 and 2 in spacer

ring.
• Grease the guide surfaces of the
centripetal pump as specified in the
lubrication schedule (see 4.3.4).
• Fit spacer ring.
Fig. 218
• Pay attention to section 4.7.1.

2065-9001-202 / 0613 157
4.4.8 Replacing the polyamide gasket (bowl top)

• For standard tools, see section 2.8.
• For special tools, see sections 2.9, 2.9.1 and 2.9.2.
REMOVAL
ATTENTION: Sensitive bowl part!

– Do NOT damage the bowl top
groove when drilling!
• Drill through the damaged polyam-

ide gasket twice centrically and
vertically:
– with a 2 mm drill bit
– at a distance of approximately 50
to 60 mm.
Fig. 219
ATTENTION: Sensitive bowl part!

– Do NOT damage the bowl top
groove when screwing in!
• Screw two wood screws into the
holes in the polyamide gasket.
• Force off the old polyamide gasket
with the wood screws and
• incrementally lever it out of the
groove using a screwdriver.
Fig. 220
Note:
If the polyamide gasket cannot be removed, repeat this procedure multiple
times.

158 2065-9001-202 / 0613
FITTING
Important! To facilitate fitting, thoroughly clean dry the groove and poly-
amide gasket in the bowl top.
• Thoroughly clean and wipe dry the groove.
CAUTION: Risk of burns due to hot water and touching hot surfaces!
– Wear protective gloves.
– Act in a safety-conscious way.
•
o
Heat the polyamide gasket in approx. 80 C (176 °F) water for 5 minutes.
• Thoroughly wipe dry the polyamide gasket.
• Fit the polyamide gasket into the

groove of the bowl top (with the nar-
row side facing the bowl top).
• Place on a smooth wooden block.
• Hammer the polyamide gasket
evenly into the groove.
Fig. 221
• Assemble the bowl and centripetal pump and fit into the separator (see sec-
tion 4.4.7 “Assembling the bowl”).
• Close the hood (see section 4.5 “Closing the hood”).
• Start the separator (see section 3.3 “Starting the separator”).
IMPORTANT! Do not start the program!

Only after a running time of 30 minutes
• Start the program.
This running time must be adhered to so that the polyamide gasket is pressed
properly into the bowl top.
If the separator is switched off by the program,

• switch on the separator motor by pressing the start key.
• Compare the starting current and starting time with the diagram (see sec-
tion 4.1.3) until the bowl reaches the speed specified on the separator name-
plate.
Note on D10 control:

The run-up phase of the separator motor is signalled by slow flashing of the
LED in the “Status Separator” key.
Note on E40 control:

The run-up phase of the separator motor is displayed by a graphical repre-
sentation of the separator motor in the control unit. Refer to the graphical rep-
resentation for “motor run-up and post-running” in the control unit manual.

2065-9001-202 / 0613 159
4.4.9 Replacing the polyamide gasket (annular piston)
Important: Time-consuming installation!

Change the polyamide gasket only when it is damaged.
• For standard tools, see Section 2.8.
• For special tools, see Sections 2.9, 2.9.1 and 2.9.2.
REMOVAL
ATTENTION Sensitive bowl part!

– Do NOT damage the annular piston
groove when drilling!
• Drill through the damaged polyam-

ide gasket twice centrically and
vertically:
– with a 2 mm drill bit
– at a distance of approximately 50
to 60 mm.
Fig. 222
ATTENTION Sensitive bowl part!

– Do NOT damage the annular piston
groove when screwing in!
• Screw two wood screws into the
holes in the polyamide gasket.
• Force off the old polyamide gasket
with the wood screws and
• incrementally lever it out of the
groove using a screwdriver.
Fig. 223
Note:
If the polyamide gasket cannot be removed, repeat this procedure multiple
times.

160 2065-9001-202 / 0613
FITTING
Important: To facilitate fitting, thoroughly clean dry the groove and poly-
amide gasket in the annular piston!
• Thoroughly clean and dry the groove.
CAUTION Risk of burns due to hot water and touching hot surfaces!
• Heat the new polyamide gasket in approx. 80 C (176 °F) water for 5 minutes.
o
• Wipe the gasket dry and press it

evenly and firmly into the groove, at
four opposite points.
Fig. 224
• Insert annular piston 1 into bowl

bottom 2.
Fig. 225

Compressing device
– Eye bolt 1
Fig. 226

2065-9001-202 / 0613 161
• Turn sliding piston 3 through 180

o
(compared to fitting position).

• Place sliding piston 3, bell-shaped
piece 2 and eye bolt 1 on the annu-
lar piston.
Fig. 227
• Press the annular piston 1 into the

bowl bottom by turning hexagon nut
2 clockwise with the wrench.
• Remove special tools and sliding

piston.
Fig. 228
• Insert gaskets 1, 2 and 3 in the

grooves of the closing chamber bot-
tom.
• Grease guide surfaces as specified
in the lubrication schedule
(see 4.3.4).
Fig. 229
• Clamp mounting ring 1 under the rim

of the closing chamber bottom.
Fig. 230

162 2065-9001-202 / 0613
• Insert closing chamber bottom 1 into

the annular piston.
• Check "O" marks of the closing
chamber bottom and the bowl bot-
tom.
Fig. 231
• Fasten closing chamber bottom 1

onto the bowl bottom by tightening
Allen screws 2 crosswise.
Fig. 232

– Socket wrench 1
• Screw tight the Allen screws holding

the closing chamber bottom and the
bowl bottom together.
Tightening torque: 25 Nm
Fig. 233
• Insert spindle screw 1 into the hub.
Fig. 234

2065-9001-202 / 0613 163
• Unscrew the Allen screws holding

the bowl bottom and the closing-
chamber bottom together.
Fig. 235

– Eye bolt 1
– Assembling device 3
Fig. 236

shaped piece 2:
piece 2
– Screw eye bolts 1 into hexagon
nut 3 by approx. 20 mm.
Fig. 237
• Place the bell-shaped piece with

fitted eye bolt into the bowl bottom.
• Fit assembling device 3 onto the
bell-shaped piece.
• Loosen three Allen screws 4 using
the ratchet wrench (with extension
and socket).
• Slip three disks 5 of the assembling
device towards the periphery, under
the rim of annular piston 6.
• Make sure that disks 5 are properly
positioned in the mounting groove of
Fig. 238
the annular piston.
• Firmly re-tighten Allen screws 4.

164 2065-9001-202 / 0613
• Force off closing chamber bottom 3

together with annular piston 4 by
turning wrench 5 clockwise.
Fig. 239
• Remove closing chamber bottom 3

and annular piston 4 (with fitted gas-
kets) with the bell-shaped piece and
the eye bolt.
the eye bolt.
Fig. 240
• Separate annular piston 1 from clos-

ing chamber bottom 2 by tapping
with a mallet – as illustrated.
• Remove the mounting ring.
Fig. 241

2065-9001-202 / 0613 165
• Unscrew the spindle screw.
Fig. 242
• By carrying out several measure-

ments around the entire circumfer-
ence of the annular piston, check
that the polyamide gasket is seated
parallel in the groove.
Fig. 243

166 2065-9001-202 / 0613
4.4.10 Reworking the sliding piston

The bowl seal consists of
• the sealing surface A of the sliding piston (Fig. 244) (Sealing surface A as de-
livered 2 mm high) and
• the polyamide gasket B of the bowl top (Fig. 246).
When worn, the sealing surface A of

the sliding piston can be remachined
up to max. 0.5 mm several times be-
fore it has to be replaced.
When the first erosion marks (0.2

mm deep) are detected, i.e. as soon
as the bowl starts to leak:
• Remachine the sealing surface of
the sliding piston.
Fig. 244
• When remachining, make sure that

– the sealing surface is machined
cleanly and
– shoulder H at diameter X is still at
least 1.5 mm high.
Fig. 245
Standard parameters for remachining the sealing surface

Surface quality Ra 2 µm (Rz 12.5 µm)
Tool Hard metal steel of ISO quality M 30 or K 20
-1
Speed 55 min
Cutting depth max. 0.15 mm
Forward feed max. 0.1 mm/revolution
After facing
• fit a new polymide gasket B into the
bowl top (see section 4.4.8)!
Fig. 246

2065-9001-202 / 0613 167
4.5 Closing the hood
If the gasket has been removed to

keep to the service intervals:
• insert a new gasket 1 in the groove
of the upper part of the frame.
Fig. 247
CAUTION: Danger of injury!

• Unlock the shackle.
• Carefully close the hood.
Fig. 248
• Screw in three hex head screws (M

12 x 30) with washers.
Fig. 249

168 2065-9001-202 / 0613
If the gaskets 2 have been removed

to keep to the service intervals:
• Provide handle connection piece 1
with new gaskets 2.
• Apply a thin coat of grease to the

guide surfaces and threads of the
handle connection piece as speci-
(see 4.3.4).
Fig. 250

– Offset screwdriver 2
• Introduce handle connection piece 1

into the hood.
• Hold the centripetal pump with the
offset screwdriver and tighten it by
lightly hammering the handle con-
nection piece with a mallet (left-
hand thread).
Fig. 251
• Carefully clean the holes in the non-

return valve and
• rinse with water.
• Check the functionality of the non-
return valve.
Fig. 252
• Assemble the filling and displace-

ment water line 1 and connect it.
Fig. 253

2065-9001-202 / 0613 169
Note
注释
Noter
Notas
Notes
‫وﺗﻼﺣظ‬
Notater
Notatki
Notizen
Notities
Бележки
Pastabos
Märkmed
Anotaciones
Muistiinpanot

170 2065-9001-202 / 0613
4.6 Drive
Fig. 254 Exploded view of the drive

2065-9001-202 / 0613 171
Pos. Designation Dimensions
1 Retaining ring 95 x 3
3 Clutch pulley
4 Grooved ball bearing
5 Spacer bush
8 Clutch shoe
9 Clutch driver
10 Washer
12 Washer 11 x 27 x 4
13 Hex head screw M 10 x 65
14 Drive belt
15 Spindle
17 Bearing cover
18 Bearing cover
20 Retaining ring 35 x 1.5
21 Ball bearing protection ring
22 Angular contact ball bearing
23 Bearing sleeve
24 Gasket
25 Rubber-metal bush
26 Pivoting bearing
28 Gasket
29 Bearing cover
(This hex head screw is glued in with Loctite 275.)

(This hex head screw is glued in with Loctite 275.)
33 Washer
34 Cup spring

172 2065-9001-202 / 0613
4.6.1 Important instructions for fitting and removing the drive

• Switch off the main switch and lock it to prevent it being switched back on.

still.
Standstill of the drive belt

• Shine a torch through the sight glass
in the frame,
• carry out a visual check to ensure
that the drive belt is no longer mov-
ing.
Fig. 255
If the sight glass in the frame is not clear:

CAUTION Danger of injury from rotating drive belt!
• Only carry out a visual check to ensure that the drive belt is no longer moving.
– Do not touch the drive belt through the sight glass opening in the frame!

If a drive belt is torn, defective or has come off:
still.
• Be sure to observe the stopping time of 90 minutes until dismantling the
separator!
CAUTION Danger of injury from very hot separator parts!

When carrying out maintenance work, there is a danger of injury from hot sepa-
o
rator parts (separating temperatures of 70 to 100 C (158 – 212 °F)).

2065-9001-202 / 0613 173
CAUTION Danger to life and limb from electric current!

Potential residual voltage!
terminal box are possible even if the main switch is off!

• refer to the motor instruction manual.
• Refer to the frequency converter manual (option).
the local electric power company).
• Any work on the motor may be carried out only by an authorised electri-
cian!
• Avoid damage to drive parts when fitting and removing through:




• Handle all drive parts gently and always set them down on a rubber mat or a
wooden pallet.
ATTENTION Before fitting the drive parts

• Thoroughly clean and dry the drive chamber.
Use only a cleaning agent that is approved for the field of application!
• Thoroughly clean and dry the spindle parts.
– Use only a cleaning agent that is approved for the field of application!
– Thoroughly clean all bores.
• Check the roller bearings of the spindle and centrifugal clutch (if applicable).
Use only the roller bearings specified in the parts list!
ATTENTION Avoid damage to the bearings!

• Always operate the separator with installed bowl.

174 2065-9001-202 / 0613
4.6.2 Removing the drive belt and spindle assembly
• Pay special attention to section 4.6.1.
• Undo the oil drain screw and

• drain the oil into an oil pan (approx.
2.5 l).
Fig. 256
• Remove three hex head screws 1.

• Remove cover 2.
Fig. 257
• Unscrew four hex head screws 1.
Fig. 258

2065-9001-202 / 0613 175
• Pull the motor with hoist out of the

flange guide (about 5 mm).
– Drive belt is slackened!
IMPORTANT!
• Pull off the drive belt from the clutch
pulley (centrifugal clutch) down-
wards.
Fig. 259
• Lift the motor with centrifugal clutch

out of the lower section of frame.
Fig. 260
Remove operating water feeding

device in the upper section of the
frame:
• Undo nut 2.
• Take off pipe 3.
Fig. 261
• Remove spindle cap 1 with fitted

gasket.
Fig. 262

176 2065-9001-202 / 0613

• Take out ring 2 and protective cap 3
with fitted gasket 4.
Fig. 263
Dismantling the speed monitoring

device:
• Unscrew hex head screw 1.
• Remove speed monitoring device 2
and place it into the lower section of
the frame.
Fig. 264
• Remove the drive belt from the low-

er section of the frame.
Fig. 265
• Undo three hex head screws 1.

• Remove spindle assembly 2 from
the lower section of the frame.
(For dismantling the spindle assem-
bly, see section 4.6.3).
Note:
If the rubber-metal bush is also pulled out
of the frame,
• loosen it from the spindle assembly by
striking the spindle on a wooden sur-
face.
Fig. 266

2065-9001-202 / 0613 177
• Remove from the lower section of

the frame:
– Gasket 1
– rubber-metal bush 2
Fig. 267
If necessary:
• Remove bearing cover 2 with
sealed-in hex head screws, washer
and cup springs 3 from the lower
Fig. 268
If necessary:
• Take out gasket 1.
Fig. 269

178 2065-9001-202 / 0613
4.6.3 Dismantling the spindle assembly
Spindle assembly
Required tools:
– pulling device
– open ended wrench
– pliers with outer snap jaws
Fig. 270
• Detach the bearing sleeve 1 from

the spindle.
Fig. 271

2065-9001-202 / 0613 179
• Pull off from the spindle:

– angular contact ball bearing 2
– ball bearing protection ring 3
Fig. 272
• Remove the retaining ring.
Fig. 273
• Pull off from the spindle:

– grooved ball bearing 1
– bearing cover 2
– bearing cover 3
Fig. 274

180 2065-9001-202 / 0613
4.6.4 Dismantling the centrifugal clutch

• Remove cover 2.
Fig. 275
Fig. 276
• Pull the motor out of the flange

guide (approx. 5 mm).
– Drive belt is slackened!
ATTENTION !
• Pull off the drive belt from the clutch
pulley (centrifugal clutch) down-
wards.
Fig. 277

2065-9001-202 / 0613 181

– Do not step under suspended loads.
• Lift the motor with centrifugal clutch

out of the lower part of the frame.
Fig. 278
CAUTION: Danger to life through

rolling away and overturning!
– Secure the motor with suitable aids
(e.g. wedges).
• Set down the motor with fitted parts
on an even surface (mat or wooden
pallet) using a hoist, turn through
o
90 (opposite the fitting position) and
secure.
Fig. 279
• Undo retaining ring 1.

• Remove disk 2.
Fig. 280
• Take the clutch shoes out of the

clutch driver.
Fig. 281

182 2065-9001-202 / 0613
• Arrest the clutch driver 1 with the

wrench.
• Unscrew hex head screw 2 out of
the motor shaft end.
• Remove disk 3.
Fig. 282

– Threaded pin 2 = M 16 x 50
• Arrest the clutch driver 1 with the

wrench.
ATTENTION : Sensitive part!

– Do not damage the motor shaft end.
• Screw threaded pin 2 into the thread
of the motor shaft end.
Fig. 283
Required special tools:

– Eye bolt 1
– Wrench 3

• Screw eye bolt 1 into the clutch driv-
er.
• Arrest the clutch driver with an open-
ended wrench.
• Force the centrifugal clutch off the
motor shaft end by turning the eye
bolt clockwise.
Fig. 284
• Remove eye bolt 1 from the clutch

driver and threaded pin 2 from the
motor shaft end.
Fig. 285

2065-9001-202 / 0613 183

– Do not step under suspended loads.
• Place the clutch driver with the aid of
transport ropes and hoist on wooden
supports.
(e.g. wedges).
• Take the retaining ring out of the
clutch driver groove.
Fig. 286
• Place on a wooden block.

• Drive the clutch driver downwards
using light hammer blows.
• Loosen the clutch driver form the
seat of the two ball bearings.
Fig. 287
• Turn the clutch pulley through 90

o
(opposite the fitting position) with the

aid of the hoist.

(e.g. wedges).
• Loosen the retaining rings from the

clutch pulley grooves.
Fig. 288
Required tools
– Disk (Ø 86 – 94 mm)
– Wooden block
– Hammer
• Turn clutch pulley through 180 .

o
• and place on wooden supports as

illustrated.
• Drive the grooved ball bearing out of
the clutch pulley.
Fig. 289

184 2065-9001-202 / 0613
4.6.5 Fitting the spindle assembly

• For dimensions of the parts, see 4.6 – exploded view.
If necessary:
• Insert gasket (1) in the groove in the
Fig. 290
If necessary:
ATTENTION: Pay attention to the

correct fitting position of the cup
springs 2!
• Fit bearing cover (1) (with sealed
hex head screws and washer) with
cup springs (2) and bolt tight with
three hex head screws (3).
Fig. 291

correct fitting position of the rub-
ber-metal cushion!
– The two opposite inner bores (2) of
the rubber-metal cushion must be
directed upwards.
• Fit rubber-metal cushion (1).
• Insert gasket (3) in the groove in the
Fig. 292

2065-9001-202 / 0613 185
• Turn spindle through 180 (upside

o
down).

correct fitting position of the neck
bearing bridge!
• Mount bearing covers (1) and (2).
CAUTION: Risk of burns due to hot

oil and by touching hot surfaces!
Fig. 293
• Heat grooved ball bearing (3) to 100 C (212 F) in an oil bath and slide it onto
o o
the spindle.
• Insert retaining ring (4) into the spindle groove.

• Heat the ball bearing protection ring
(1) and angular contact ball bearing
o o
(2) in an oil bath to 100 C (212 F).
Fig. 294
ATTENTION: Bearing failure due to incorrect fitting!

– When mounting angular contact ball bearing (2) on the spindle, make sure
that the narrow rim of the ball bearing inner ring is directed upwards.
• Slide ball bearing protection ring (1) and angular contact ball bearing (2) onto
the spindle.

• Heat the bearing sleeve (1) in an oil
o o
bath to 100 C (212 F).
• Important! Prior to fitting bearing
sleeve (1), ensure that the fitted an-
gular contact ball bearing has cooled
down to room temperature.
Fig. 295
• Slide bearing sleeve (1) over the angular contact ball bearing and the ball
bearing protection ring.

186 2065-9001-202 / 0613

correct fitting position of the spin-
dle!
– The holes in the upper bearing cover
(1) must be aligned with the tap-
holes in the lower part of the frame.
– The holes in bearing sleeve (3) must
face the hex head screws (4) and (5)
in the lower bearing cover.
• Install the assembled spindle in the

lower section of frame.
– Ensure it is locked in position!
• Bolt tight the mounted spindle with
three hex head screws (2).
Fig. 296

2065-9001-202 / 0613 187
4.6.6 Fitting the centrifugal clutch

• For dimensions of the parts, see 4.6 – exploded view.
• Clean the clutch pulley.

• Fit the retaining ring 1 in the lower
groove.
• Check that retaining ring 1 is cor-
rectly fitted. .
Fig. 297
Required tools:
– Disk 2 (Ø 86 – 94 mm)
– Wooden block
– Hammer
ATTENTION: Ball bearing failure

due to incorrect fitting!
– Disk 2 may have contact only with
the outer ring of grooved ball bear-
ing 1.
• Carefully drive the first grooved ball

bearing 1 with disk 2 up to the re-
taining ring.
Fig. 298

188 2065-9001-202 / 0613

– Distance bush 1 may only contact
the inner ring of grooved ball bearing
2!
• Position the distance bush 1 on the

ball bearing inner race.
Fig. 299

– Disk 2 may have contact only with
the outer ring of grooved ball bear-
ing 1.
• Carefully drive the second grooved

ball bearing 1 with a suitable disk 2
up to the distance sleeve.
Fig. 300
CAUTION: Danger of imbalance by

incorrect fitting!
• Insert retaining ring 2 180 offset
o
relative to retaining ring 1 in the up-

per groove.
Fig. 301

2065-9001-202 / 0613 189
Required tool:
– Disk 1 (Ø 61 – 69 mm)

• Turn the clutch pulley with fitted
o
grooved ball bearings through 180 .
Fig. 302
ATTENTION: Ball bearing failure due to incorrect fitting!

– Disk 1 may only contact the inner race of the grooved ball bearing!
• Place the ball bearing inner race on disk 1.

correct fitting position of the dis-
tance bush!
– Distance bush 1 must be flush with
the inner rings of the grooved ball
bearings.
Fig. 303
Required tools:
– Wooden block
– Rubber hammer
• Carefully hammer the clutch driver

into the grooved ball bearing with
light blows.
Fig. 304

190 2065-9001-202 / 0613
• Turn clutch pulley through 180 .

o
• Fit the retaining ring in the groove of

the clutch driver.
Fig. 305

CAUTION: Danger to life from roll-

ing away and overturning!
(e.g. wedges).
• Set down the motor on an even
surface (mat or wooden pallet) using
o
a hoist, turn through 90 (opposite
the fitting position) and secure.
Fig. 306
Required tools:
– Ring spanner 2
– Hex head screw 3 (M 10 x 200)
– Hexagon nut 4 (M 10)
• ATTENTION: Pay attention to the

feather key groove.
• Fit the mounted centrifugal clutch on
the motor shaft end.
• Arrest clutch driver 1 with the
wrench.
• Insert ring spanner 2 - as shown -
and
• Screw hex head screw 3 with hexa-
gon nut 4 into the motor shaft end.
Fig. 307

2065-9001-202 / 0613 191
• Pull the centrifugal clutch onto the

motor shaft end as far as it will go by
turning hexagon nut 4 with a second
wrench.
Fig. 308
• Unscrew hex head screw 3 with

hexagon nut 4 and
• detach ring spanner 2.
Fig. 309
When clutch driver 1 is arrested:

• Provide hex head screw 2
(M 12 x 60) with washer 3 and
thread it into the motor shaft end.
Fig. 310
CAUTION: Danger of imbalance!

– Be sure to replace all clutch shoes
simultaneously!
Never replace individual clutch
shoes.
– Make sure that the clutch shoes are
evenly spaced!
• Check thickness of clutch shoes.

– Replace clutch shoes when h is
smaller than 18 mm.
• Fit the clutch shoes.
Fig. 311

192 2065-9001-202 / 0613
• Fit washer 2.
• Fit the retaining ring 1 in the groove
of the clutch driver.
Fig. 312

2065-9001-202 / 0613 193
4.6.7 Fitting the motor

• Carefully position the motor with
mounted centrifugal clutch on the
lower section of the frame with the
aid of a hoist.
– Do not yet let the motor flange
register in the opening in the
frame.
Fig. 313
ATTENTION:
• Remove the grease from the belt
running surfaces of the spindle and
clutch pulley.
• Mount the flat belt:
– through the frame upper part
opening 1 and
– through the brake housing 2 (cen-
trifugal clutch).
• Ensure the drive belt is correctly
positioned on the clutch pulley and
the spindle pulley.
Fig. 314
• Remove screw plug 1 from the lower

Fig. 315

194 2065-9001-202 / 0613
ATTENTION: Avoid damage to the

grooved ball bearing.
– Do not screw in hex head screw 1
all the way.
• Screw hex head screw 1 (M 10 x
200) with hexagon nut 2 and washer
3 through the frame bore into the
taphole of the centrifugal clutch.
• Tension the drive belt by turning
hexagon nut 2 clockwise until the
motor flange engages in the frame
opening.
Fig. 316
• Secure the motor with four hex head

screws 2 (M 12 x 30).
• Unscrew hex head screw 1 (with

hexagon nut and washer) from the
centrifugal clutch.
Fig. 317
• Screw in the screw plug 1.

• Remove the hoist.
Fig. 318
Note:
Due to the design concept used, the spindle is at an inclined angle relative to
the opposite side of the motor when the drive belt has not been fitted or ten-
sioned (see Fig. 319, pos. 2).
The spindle is pulled into the centric axis when the belt is tensioned (see Fig.
319, pos 1)!

2065-9001-202 / 0613 195
• Check
– that the spindle 1 can be turned
easily.
– whether the spindle has been
pulled into the centric axis by
tensioning the drive belt 3
(see Fig. 209.)
Fig. 319 Example of a spindle
Fitting the speed monitoring device:
• Position speed monitoring device 2

on the lower section of the frame
and
• fasten with Allen screws 1.
Fig. 320
IMPORTANT!
The distance X between spindle and
proximity switch must be 3.5 mm.
• Align proximity switch 1 as illustrat-
ed.
Fig. 321
• Insert protective cap 3 with fitted

gasket 4 and ring 2 and
• secure with four hex head screws 1
(M 8 x 12).
Fig. 322

196 2065-9001-202 / 0613
• Place spindle cap 1 with fitted gas-

ket on the spindle.
ing!
Fig. 323
Fit operating water feeding device

in the upper section of the frame:
• Slide nut 2 over pipe 3.
correct fitting position.
– The narrow end of the pipe must
point upwards!
• Fit pipe 3 with nut 2 into the screwed
connection 1 and slide on as far as it
will go.
• Tighten nut 2 firmly.
Fig. 324
• Fit cover 2 to the lower section of

the frame with three hex head
screws 1 (M 8 x 20).
Fig. 325
• Screw in oil drain screw 1 with fitted

gasket.
• Screw in sight glass 2.
• Fill in oil as described in sec-
tion 4.3.3 and
• screw in the plug 3 with gasket.
Fig. 326

2065-9001-202 / 0613 197
CAUTION: Danger to life and limb

through electric current!
• Have the motor connected by an
authorised electrician!
Fig. 327 Example of a motor

198 2065-9001-202 / 0613
4.7 Height adjustment
For reasons of operating reliability, adjustment of

• bowl height
• and centripetal pump play
must be performed with particular care.
4.7.1 Bowl height
ATTENTION: The bowl height must not be adjusted on this separator!

The bowl height may only be measured when the belt drive is fitted and
tightened.
A bowl height check is necessary:
– after replacing the drive parts,
– after fitting another bowl,
– after fitting a different centripetal pump,
– as soon as the centripetal pump exhibits grinding marks.
CAUTION: A loose bowl top can

endanger life!
• Tighten the bowl top firmly.

• Check “O” marks on the bowl bottom
and bowl top.
– The “0” marks must be aligned.
Fig. 328
The check dimension A

– is 33.5 ±2 mm
– between upper edge of bowl top and
upper section of frame.
Fig. 329
If it does prove necessary to readjust the bowl height, consult the factory.

2065-9001-202 / 0613 199
4.7.2 Centripetal pump clearance
• Move the centripetal pump axially to

and fro in the centripetal pump
chamber.
– Measure the total clearance A
(approx. 10 mm).
• Close the hood.
• Check:
– Is the hood correctly seated on
the frame rim?
– Are the hood screws tightened
firmly?
Fig. 330
• Lightly apply a thin coat of lubricant

to the threads of the centripetal
pump as specified in the lubrication
schedule.
• Fit handle connection piece 1 into
the centripetal pump.
• Hold the centripetal pump with offset
screwdriver 2.
• Screw handle connection piece into
the centripetal pump as far as it will
go (left-hand thread).
Fig. 331
• Hold the handle connection piece 1.

• Turn the offset screwdriver 2 until
the handle connection piece is
raised slightly from the hood (ap-
prox. 0.5 mm).
Fig. 332

200 2065-9001-202 / 0613
• Raise the handle connection piece

to its maximum.
• Measure the axial clearance.
A/2 = 4 – 6 mm
Fig. 333

2065-9001-202 / 0613 201
4.8 Final checks after assembling the separator
Before starting the separator

Perform the following checks after assembling and before starting the separator
depending on the scope of the repair work:
Check Section
Bowl height 4.7.1

Oil level in drive chamber 4.3.3
Direction of rotation of the bowl 4.1.4
Bowl speed 4.1.5
Starting time of bowl / current consumption 4.1.5
Running characteristics of the separator 3.8.1
Suction line of the product pump (if fitted) for leakage
When starting the separator

Perform the following checks after carrying out repairs:
Check Section
Temperature of product Operating

datasheet
Observe at all discharges whether the bowl is functioning 3.3
correctly
4.9 Before a long-term shut-down of the separator

• Disconnect all electrical connections.
• Thoroughly clean the separator (see section 4.4.2, 4.4.3 and 4.4.4).
• Dry and grease the clean bowl parts and all unvarnished machine parts to
avoid corrosion damage.
• Store the clean, greased bowl in a dry place until reuse.
• Store the gaskets in a cool, dry, dust-free dark room to prevent them from be-
coming brittle.
• Check if the shut-off valves for water leak.
• If necessary, disconnect the water lines to prevent damage by dripping water.
4.9.1 Preserving the separator

• Drain the lube oil completely.
Observe the local regulations on disposal of the lubricating oil.

202 2065-9001-202 / 0613
• Fill the drive chamber with a slushing oil, e.g. Shell oil S.7294 (SAE 30/SAE
50), to the middle of the sight glass.
• Let the separator run without bowl for approx. 1 minute to make sure that all
drive parts are coated with slushing oil.
CAUTION!
Risk of injury through rotating separator parts.
• Keep a safe distance away from the rotating spindle.
• After switching off the separator, wait until the spindle has stopped rotating.
• Take off the drive belt.
4.9.2 Preserving the motor

• Follow the instructions of the motor manufacturer.

2065-9001-202 / 0613 203
4.10 Storage
ATTENTION: Improper and incorrect storage of the separator and control

unit can damage or destroy their components!
– Outdoor storage is not admissible!
• Store accessories like spare parts, tools, lubricants properly!
Note:
Gaskets, hoses and hosepipes, for example, change their physical properties in
unfavourable storage conditions. This can result in a shorter service life. They
can be rendered useless due to excessive hardening, softening, permanent de-
formation, flaking, cracks or other surface damage.
4.10.1 After delivery

If the separator and control unit are not installed immediately after delivery,
• store the separator and control unit in the original transport packaging.
Recommended storage temperature: + 5 bis +50 °C (41 – 122 °F)

storage times!
– A storage time of more than 12 months of the separator and control unit is
only admissible after consulting the manufacturer.
In the case of short-term storage (up to 24 months):

• Check all separator parts in accordance with the maintenance schedule and
– See table "Maintenance every 4000 operating hours – after no more than 6
months at the latest"
– or see table "Maintenance every 8000 operating hours – after no more than
1 year at the latest"
In the case of long-term storage (longer than 24 months):

est".
4.10.2 Separator
The following procedure applies
– for storing the separator before commissioning and
– for storing the separator before a prolonged standstill period.
ATTENTION:
• Store the separator with dismantled bowl!
• Store the clean, greased bowl in a dry place.

• The gaskets should be kept in a cool, but frost-free, dry room, protected from
dust and light, to prevent them from getting brittle.
Recommended storage temperature: + 5 bis +50 °C (41 - 122 °F)
• The separator must be stored in stable and dry conditions.
(Vibrations during standstill can cause bearing damage!).
• Protect the drive spindle and motor against dust.

204 2065-9001-202 / 0613
• Store all other separator parts dry and frost-free.
4.10.3 Control system

• The control unit and accessories must be stored dry, dust-free, vibration and
frost-free.
• Protect from excessive heat!
Recommended storage temperature: + 5 bis + 45 °C (41 – 113 °F)
4.11 Before restarting
Before restarting, the operator must ensure

• that all separators and plant components are checked for proper func-
tion by competent personnel (qualified specialists).
• that the maintenance intervals are adhered to.
• that the separator is assembled correctly by competent persons.

standstill or storage times!
If the bowl has been opened for longer than 6 months,
• check all bowl parts in accordance with the maintenance schedule and re-
place when necessary.
months at the latest".
• check all separator parts in accordance with the maintenance schedule and
year at the latest".
est".
Procedure:
• Drain the slushing oil.
Observe the local regulations on disposal of the slushing oil.
• Remove the grease from all unpainted machine elements.
ATTENTION: Fit only gaskets that are in perfect condition!

• Check the gaskets for damage.
• Assemble the bowl (see section 4.4.7).
ATTENTION: Fit only roller bearings that are in perfect condition!

• Check the roller bearings of the spindle and centrifugal clutch (if applicable).

2065-9001-202 / 0613 205
ATTENTION: Fit only drive belts that are in perfect condition!

• Check the drive belt for damage.
• Assemble the separator correctly.

• Fill the drive chamber with the specified lubricating oil as specified in
tion 4.3.3.
4.12 Disposal
When the equipment is no more useful or the separator has reached the end of
its service life, the operator is responsible for appropriate, environmentally
friendly disposal of its components and materials such as
– metal,
– caoutchouc and rubber
– plastics,
– glass,
– gear and lube oils on a mineral-oil basis,
– synthetic gear and lube oils,
– cleaning liquids,
– electric and electronic apparatus.
ENVIRONMENTAL PROTECTION!
Be sure to adhere to applicable environment-protection legislation!
More information on disposal matters can be obtained from local authorities.
4.12.1 Gear and lubricating oils
Replacement and disposal of waste

oils recovered during the oil changes
and maintenance work must be carried
out carefully.
• Collect dripping oil to prevent danger
of slipping or product infection.
• They can be injurious to health,
depending on their chemical compo-
sition.
• Waste oil must be disposed of in
Note:
Fig. 334
Special attention must be paid to
the directive issued by the operator
on handling waste oils and the local
regulations.

206 2065-9001-202 / 0613
4.12.2 Cleaning fluids

Only those cleaning agents may be used that are specified in the overall docu-
mentation (see data sheet).
CAUTION: Danger of chemical burns!

The cleaning agents can be acids and caustics which, if used carelessly,
can cause severe damage to persons.
– Wear personal protective gear.
• Refer to the SOP issued by the plant operator on handling the cleaning fluids
used.
• Observe the local disposal regulations.
• Be sure to adhere to applicable environmental protection legislation.
4.12.3 Separator
Before disposing of the separator
• Drain the gear oil and dispose of it properly in accordance with section 4.12.1.
• Dismantle the separator, remove any lubricant sticking to separator parts and
dispose of them separately or recycle them where appropriate.

2065-9001-202 / 0613 207
5 Spare parts
5.1 Spare part requirements ...................................................................... 208

5.2 Guide to ordering spare parts .............................................................. 208

208 2065-9001-202 / 0613
5.1 Spare part requirements
• Use only genuine spare parts from GEA

Westfalia Separator Group. The genuine
spare parts are listed in the spare parts cata-
log.
– Safety risks
– Reduced durability of these parts
– Reduced availability of the separator
Fig. 335
– Increased service requirement
If a safety risk occurs when using non-genuine
for the responsible persons. In such cases, the
GEA Westfalia Separator Group accepts no lia-
bility or warranty claims.
5.2 Guide to ordering spare parts

A rapid and correct supply of spare parts can only be guaranteed if your order
includes the following details:
• Separator model see name-plate

e.g. OSE 10-91-067
• Serial-No. see name-plate

e.g. 9000-223
• Designation see order-specific parts catalog

e.g. frame
• Part Number see order-specific parts catalog

e.g. 2050-1100-020
The part number is also marked on almost all the
individual parts.
Only when ordering spare parts for bowls:

• Bowl S/N If this differs from the serial number.
The bowl serial number is engraved on the bowl
lock ring, bowl bottom and bowl top.
Only required when ordering spare parts for pump and pump connection parts:
• Model and number of see pump nameplate

pump
The information provided must be complete to avoid incorrect deliveries.
Available sets of spare parts

The following sets of spare parts are available depending on the respective
technical maintenance intervals:
– Set of spare parts “bowl and hood” for operation of 1 year or 8000 hours
– Set of spare parts “Drive” for operation of 1 year or 8000 hours
– Set of spare parts “Drive” for operation of 2 years or 16,000 hours
The maintenance schedule forms the systematic maintenance basis for the use
of these sets of spare parts.

2065-9001-202 / 0613 209
Note
注释
Noter
Notas
Notes
‫وﺗﻼﺣظ‬
Notater
Notatki
Notizen
Notities
Бележки
Pastabos
Märkmed
Anotaciones
Muistiinpanot

210 2065-9001-202 / 0613
Note
注释
Noter
Notas
Notes
‫وﺗﻼﺣظ‬
Notater
Notatki
Notizen
Notities
Бележки
Pastabos
Märkmed
Anotaciones
Muistiinpanot

We live our values.
Excellence • Passion • Integrity • Responsibility • GEA-versity
GEA Group is a global engineering company with multi-billion euro sales and operations in more than
50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment
and Process technology. GEA Group is listed in the STOXX® Europe 600 Index.

Phone: +49 2522 77-0, Fax: +49 2522 77-2488
www.gea.com
P1/PX1 Engineering
Operation &
Original™ Series METAL Pumps Maintenance
Simplify your process
LISTED
79
WIL-10300-E-12
REPLACES WIL-10300-E-11
TA B L E O F C O N T E N T S
SECTION 1 CAUTIONS—READ FIRST! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SECTION 2 WILDEN PUMP DESIGNATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SECTION 3 HOW IT WORKS—PUMP & AIR DISTRIBUTION SYSTEM . . . . . . . . . . . . . . . .3
SECTION 4 DIMENSIONAL DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SECTION 5 PERFORMANCE
A. P1 Performance Curves
Rubber-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
TPE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
PTFE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
B. PX1 Performance
Operating Principal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How to Use this EMS Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Performance Curves
Rubber-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TPE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
PTFE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
C. Suction Lift Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 6 SUGGESTED INSTALLATION, OPERATION & TROUBLESHOOTING . . . . . . .20
SECTION 7 ASSEMBLY / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Grounding Strap for CSA Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
SECTION 8 EXPLODED VIEW & PARTS LISTING

P1 Rubber/TPE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
P1 PTFE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
PX1 Rubber-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
PX1 PTFE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
SECTION 9 ELASTOMER OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
II Ozone
I&
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Cle ents o
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Section 1
CAUTIONS—READ FIRST!
CAUTION: Do not apply compressed air to the exhaust port CAUTION: The process fluid and cleaning fluids must be
— pump will not function. chemically compatible with all wetted pump components.
Consult Chemical Resistance Guide (E4).
CAUTION: Do not over-lubricate air supply — excess
lubrication will reduce pump performance. Pump is pre-lubed. CAUTION: Do not exceed 82°C (180°F) air inlet temperature
for Pro-Flo X™ models.
CAUTION: Do not under any circumstance loosen the set
screw located at the adjuster dial of the Pro-Flo X™ pump. If CAUTION: Pumps should be thoroughly flushed before
the set screw is loose when the pump is pressurized, it could installing into process lines. FDA and USDA approved pumps
eject and cause injury to anyone in the area. should be cleaned and/or sanitized before being used.
TEMPERATURE LIMITS: CAUTION: Always wear safety glasses when operating

Neoprene –17.7°C to 93.3°C 0°F to 200°F pump. If diaphragm rupture occurs, material being pumped may
Buna-N –12.2°C to 82.2°C 10°F to 180°F be forced out air exhaust.
EPDM –51.1°C to 137.8°C –60°F to 280°F CAUTION: Before any maintenance or repair is attempted,
Viton® –40°C to 176.7°C –40°F to 350°F the compressed air line to the pump should be disconnected
Saniflex™ –28.9°C to 104.4°C –20°F to 220°F and all air pressure allowed to bleed from pump. Disconnect
Polytetrafluoroethylene (PTFE) all intake, discharge and air lines. Drain the pump by turning
4.4°C to 104.4°C 40°F to 220°F it upside down and allowing any fluid to fl ow into a suitable
Polyurethane –12.2°C to 65.6°C 10°F to 150°F container.
Tetra-Flex™ PTFE w/Neoprene Backed CAUTION: Blow out air line for 10 to 20 seconds before
4.4°C to 107.2°C 40°F to 225°F attaching to pump to make sure all pipeline debris is clear. Use
Tetra-Flex™ PTFE w/EPDM Backed an in-line air filter. A 5µ (micron) air filter is recommended.
-10°C to 137°C 14°F to 280°F NOTE: When installing PTFE diaphragms, it is important
to tighten outer pistons simultaneously (turning in opposite
NOTE: Not all materials are available for all models. Refer to directions) to ensure tight fi t. (See torque specifications in
Section 2 for material options for your pump. Section 7.)
NOTE: Canadian Standards Association (CSA) configured NOTE: Cast Iron PTFE-fi tted pumps come standard from the
pumps should not be used in temperatures lower than 0.0ºC to factory with expanded PTFE gaskets installed in the diaphragm
51.6ºC (32ºF to 125ºF). bead of the liquid chamber. PTFE gaskets cannot be re-used.
NOTE: UL listed configured pumps have the following Consult PS-TG for installation instructions during reassembly.
temperature limits: NOTE: Before starting disassembly, mark a line from each
UL 79 Buna- -12.2°C (10°F) to 52°C (125°F) liquid chamber to its corresponding air chamber. This line will
CAUTION: When choosing pump materials, be sure to check assist in proper alignment during reassembly.
the temperature limits for all wetted components. Example: CAUTION: Pro-Flo ® pumps cannot be used in submersible
Viton ® has a maximum limit of 176.7°C (350°F) but polypropylene applications. Pro-Flo X™ is available in both submersible and
has a maximum limit of only 79°C (175°F). non-submersible options. Do not use non-submersible Pro-Flo
CAUTION: Maximum temperature limits are based upon X™ models in submersible applications. Turbo-Flo ® pumps can
mechanical stress only. Certain chemicals will significantly also be used in submersible applications.
reduce maximum safe operating temperatures. Consult CAUTION: Tighten all hardware prior to installation.
Chemical Resistance Guide (E4) for chemical compatibility and
temperature limits.
CAUTION: The gas outlet of CSA configured pumps must be
WARNING: Prevention of static sparking — If static sparking vented to a safe location in accordance with local codes or, in
occurs, fire or explosion could result. Pump, valves, and the absence of local codes, an industry or nationally recognized
containers must be grounded to a proper grounding point when code having jurisdiction over the specified installation.
handling flammable fluids and whenever discharge of static
electricity is a hazard. CAUTION: For U.L. listed pumps, all pipe connections are to be
made using U.L. classified gasoline-resistant pipe compound.
CAUTION: Canadian Standards Association (CSA) configured
pumps must be electrically grounded using the grounding CAUTION: For U.L. listed pumps all installations must conform
location identified. Improper grounding can cause improper to NFPA 30, NFPA 30A, and all other applicable codes.
and dangerous operation.
CAUTION: For U.L. listed pumps, air exhaust port is to be
CAUTION: Do not exceed 8.6 bar (125 psig) air supply connected to pipe or tubing to be routed outdoors or other
pressure. location determined to be equivalent.
CAUTION: Canadian Standards Association (CSA) configured CAUTION: For U.L. listed pumps, pump is to be grounded
pumps should not exceed 6.9 bar (100 psig) sweet gas supply using the jam-nut located at the top of the long vertical carriage
pressure. bolt. The ground connection is marked with a tag having the
grounding symbol.
CAUTION: For U.L. listed pumps, do not exceed 3.4 bar (50
psig) air supply pressure.
Grounding Symbol
WIL-10300-E-12 1 WILDEN PUMP & ENGINEERING, LLC

Section 2
W IL DEN PUMP DESIGN AT ION SYS T EM
P1/PX1 ORIGINAL™ LEGEND xPX1 / X X X X X / XXX / XX / X XX / XXXX

METAL
O-RINGS
13 mm (½") Pump MODEL VALVE SEAT SPECIALTY
CODE
VALVE BALLS
Maximum Flow Rate: ATEX DIAPHRAGMS
AIR VALVE
(if applicable)
62.8 lpm (16.6 gpm) CENTER SECTION

WETTED PARTS & OUTER PISTON
MATERIAL CODES
MODEL AIR VALVE VALVE BALL
®
P1 = Pro-Flo A = ALUMINUM (PX1 only) BN = BUNA-N (Red Dot)
PX1 = Pro-Flo X™ G = CONDUCTIVE ACETAL (P1 FS = SANIFLEX™
®
XPX1 = ATEX Pro-Flo XTM only) [Hytrel (Cream)]
J = CONDUCTIVE PU = POLYURETHANE (Brown)
WETTED PARTS & OUTER PISTON POLYPROPYLENE (P1 only) TF = PTFE (White)
®
AA = ALUMINUM / ALUMINUM L = ACETAL (P1 only) VT = VITON (White Dot)
®
AZ = ALUMINUM / NO PISTON P = POLYPROPYLENE (P1 only) WF = WIL-FLEX™ [Santoprene
SS = STAINLESS STEEL / (Orange Dot)]
STAINLESS STEEL DIAPHRAGMS EP = EPDM (Blue Dot)
SZ = STAINLESS STEEL / XBS = CONDUCTIVE BUNA-N
NO PISTON (Two Red Dots) VALVE SEAT
BNS = BUNA-N (Red Dot) A = ALUMINUM
CENTER SECTION FSS = SANIFLEX™ S = STAINLESS STEEL
® ®
AA = ALUMINUM (PX1 only) [Hytrel (Cream)] V = VITON (White Dot)
GG = CONDUCTIVE ACETAL PUS = POLYURETHANE (Clear)
(P1 only) TEU = PTFE w/EPDM VALVE SEAT O-RING
JJ = CONDUCTIVE BACK-UP (White) BN = BUNA-N
POLYPROPYLENE (P1 only) THU = PTFE W/HIGH-TEMP FS = SANIFLEX™
®
LL = ACETAL (P1 only) BUNA-N BACK-UP (White) [Hytrel (Cream)]
PP = POLYPROPYLENE (P1 only) TNU = PTFE W/NEOPRENE PU = POLYURETHANE (Brown)
BACK-UP (White) TF = PTFE (White)
®
TNL = PTFE W/NEOPRENE WF = WIL-FLEX™ [Santoprene ]
BACK-UP O-RING, EP = EPDM
IPD (White)
®
VTS = VITON (White Dot)
®
WFS = WIL-FLEX™ [Santoprene
(Orange Dot)]
EPS = EPDM (Blue Dot)
SPECIALTY CODES
0023 Wing nuts 0120 Saniflo™ FDA, Wil-Gard II™ 110V
0067 Saniflo™ FDA, Wil-Gard II™ 220V 0206 PFA coated hardware, Wil-Gard II™
0070 Saniflo™ FDA sensor wires ONLY
0079 Tri-clamp fittings, wing nuts 0390 CSA Approved
0080 Tri-clamp fittings ONLY 0495 U.L. Approved
0100 Wil-Gard II™ 110V 0502 PFA coated hardware
0102 Wil-Gard II™ sensor wires ONLY 0603 PFA coated hardware, Wil Gard 110V
0103 Wil-Gard II™ 220V 0608 PFA coated hardware, Wil Gard 220V
NOTE: The Wilden UL 79 Listed products covered by this manual are PX1 models followed by AA or SS, followed by AA, followed by A, followed by
BNS, followed by BN, followed by A or S, followed by BN, followed by 0495. Wilden UL Listed pumps have been evaluated for use at a
25 C (77F) ambient temperature with a maximum inlet pressure of 3.4 Bar (50 PSI)..
WILDEN PUMP & ENGINEERING, LLC 2 WIL-10300-E-12

Section 3
HOW IT WORKS
The Wilden diaphragm pump is an air-operated, positive displacement, self-priming pump. These drawings show the flow pattern
through the pump upon its initial stroke. It is assumed the pump has no fluid in it prior to its initial stroke.
B A B A B A
OPEN
FIGURE 1 The air valve directs pressurized air to FIGURE 2 When the pressurized diaphragm, FIGURE 3 At completion of the stroke, the air valve
the back side of diaphragm A. The compressed air diaphragm A, reaches the limit of its discharge again redirects air to the back side of diaphragm A,
is applied directly to the liquid column separated by stroke, the air valve redirects pressurized air to the which starts diaphragm B on its exhaust stroke. As
elastomeric diaphragms. The diaphragm acts as a back side of diaphragm B. The pressurized air forces the pump reaches its original starting point, each
separation membrane between the compressed air diaphragm B away from the center block while pull- diaphragm has gone through one exhaust and one
and liquid, balancing the load and removing mechan- ing diaphragm A to the center block. Diaphragm B discharge stroke. This constitutes one complete
ical stress from the diaphragm. The compressed air is now on its discharge stroke. Diaphragm B forces pumping cycle. The pump may take several cycles
moves the diaphragm away from the center block of the inlet valve ball onto its seat due to the hydraulic to completely prime depending on the conditions of
the pump. The opposite diaphragm is pulled in by forces developed in the liquid chamber and mani- the application.
the shaft connected to the pressurized diaphragm. fold of the pump. These same hydraulic forces
Diaphragm B is on its suction stroke; air behind the lift the discharge valve ball off its seat, while the
diaphragm has been forced out to the atmosphere opposite discharge valve ball is forced onto its seat,
through the exhaust port of the pump. The move- forcing fluid to flow through the pump discharge.
ment of diaphragm B toward the center block of the The movement of diaphragm A toward the center
pump creates a vacuum within chamber B. Atmo- block of the pump creates a vacuum within liquid
spheric pressure forces fluid into the inlet manifold chamber A. Atmospheric pressure forces fluid into
forcing the inlet valve ball off its seat. Liquid is free the inlet manifold of the pump. The inlet valve ball is
to move past the inlet valve ball and fill the liquid forced off its seat allowing the fluid being pumped
chamber (see shaded area). to fill the liquid chamber.
HOW IT WORKS—AIR DISTRIBUTION SYSTEM
The Pro-Flo® patented air distribution system incorporates two

moving parts: the air valve spool and the pilot spool. The heart of
the system is the air valve spool and air valve. This valve design
incorporates an unbalanced spool. The smaller end of the spool
is pressurized continuously, while the large end is alternately
pressurized then exhausted to move the spool. The spool directs
pressurized air to one air chamber while exhausting the other.
The air causes the main shaft/diaphragm assembly to shift to
one side — discharging liquid on that side and pulling liquid in
on the other side. When the shaft reaches the end of its stroke,
the inner piston actuates the pilot spool, which pressurizes and
exhausts the large end of the air valve spool. The repositioning
of the air valve spool routes the air to the other air chamber.

Section 4
DIMENSIONAL DR AWINGS
P 1 M ETAL
DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 208 8.2
B 28 1.1
C 130 5.1
D 198 7.8
E 224 8.8
F 53 2.1
G 114 4.5
H 206 8.1
J 262 10.3
K 130 5.1
L 30 1.2
M 137 5.4
N 109 4.3
P 84 3.3
R 102 4.0
S 8 0.3
T 203 8.0
U 142 5.6
V 112 4.4
BSPT threads available. REV. E
P 1 M ETAL S A N I F LO FDA
DIMENSIONS
A 203 8.0
B 53 2.1
C 130 5.1
D 218 8.6
E 257 10.1
F 53 2.1
G 114 4.5
H 114 4.5
J 287 11.3
K 130 5.1
L 84 3.3
M 102 4.0
N 84 3.3
P 142 5.6
R 8 0.3
REV. D

DIMENSIONAL DR AWINGS
PX1 M E TA L DIMENSIONS
A 208 8.2
B 28 1.1
C 130 5.1
D 198 7.8
E 224 8.8
F 41 1.6
G 132 5.2
H 221 8.7
J 361 14.2
K 132 5.2
L 30 1.2
M 137 5.4
N 109 4.3
P 84 3.3
R 102 4.0
S 8 0.3
T 203 8.0
U 142 5.6
V 112 4.4
BSPT threads available. REV. A
PX1 M E TA L S A N I F LO FDA
DIMENSIONS
A 203 8.0
B 53 2.1
C 130 5.1
D 218 8.6
E 257 10.1
F 41 1.6
G 114 4.5
H 132 5.2
J 386 15.2
K 132 5.2
L 84 3.3
M 102 4.0
N 112 4.4
P 142 5.6
R 8 0.3
REV. D

Section 5A
PERFORMANCE
P 1 M E TAL
RUBBER-FITTED
Height.................................... 224 mm (8.8")
Width ..................................... 208 mm (8.2")
Depth .................................... 206 mm (8.1")
Ship Weight ................. Aluminum 6 kg (13 lbs)
Stainless Steel 9 kg (20 lbs)
Air Inlet ...................................... 6 mm (1/4")
Inlet .........................................13 mm (1/2")
Outlet ...................................... 13 mm (1⁄2")
Suction Lift ........................ 5.8 m Dry (19.0')
9.5 m Wet (31.0')
Displacement per Stroke . .11 l (0.029 gal.)1
Max. Flow Rate ........... 58.67 lpm (15.5 gpm)
Max. Size Solids .................1.59 mm (1/16")
1Displacement per stroke was calculated at 4.8 Bar
(70 psig) air inlet pressure against a 2 Bar (30 psig)

head pressure.
Example: To pump 18.9 lpm (5 gpm) against
a discharge pressure head of 2.7 Bar (40 Flow rates indicated on chart were determined by pumping water.
psig) requires 4 Bar (60 psig) and 5.92 Nm3/h
(3.5 scfm) air consumption. (See dot on For optimum life and performance, pumps should be specified so that daily operation parameters
chart.) will fall in the center of the pump performance curve.
Caution: Do not exceed 8.6 Bar (125 psig) air
supply pressure.
P 1 M E TAL
TPE-FITTED
Height.................................... 224 mm (8.8")
Width ..................................... 208 mm (8.2")
Depth .................................... 206 mm (8.1")
Stainless Steel 9 kg (20 lbs)
Air Inlet ...................................... 6 mm (1/4")
Inlet .........................................13 mm (1/2")
Outlet ......................................13 mm (1/2")
9.5 m Wet (31.0')
1
Displacement per stroke was calculated at 4.8 Bar
(70 psig) air inlet pressure against a 2 Bar (30 psig)
head pressure.
a discharge pressure head of 2.7 Bar (40
psig) requires 4 Bar (60 psig) and 5.92 Nm3/h Flow rates indicated on chart were determined by pumping water.
supply pressure.

PERFORMANCE
P1 M E TA L
PTFE-FITTED
Height .................................... 224 mm (8.8")
Width ..................................... 208 mm (8.2")
Depth .................................... 206 mm (8.1")
Stainless Steel 9.2 kg (20 lbs)
Air Inlet ...................................... 6 mm (1/4")
Inlet .........................................13 mm (1/2")
Outlet ......................................13 mm (1/2")
9.5 m Wet (31.0')
1Displacement per stroke was calculated at 4.8 Bar
(70 ) air inlet pressure against a 2 Bar (30 psig)
head pressure.
a discharge pressure head of 2.7 Bar (40 Flow rates indicated on chart were determined by pumping water.
psig) requires 4 Bar (60 psig) and 5.92 Nm3/h
supply pressure.

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PX1
M E T A L
PX1 PERFORMANCE
Section 5B
Pro-Flo XTM Operating Principal

The Pro-Flo X™ air distribution system with the control dial, the operator can select the optimal
revolutionary Efficiency Management System (EMS) balance of flow and efficiency that best meets the
offers flexibility never before seen in the world of application needs. Pro-Flo X™ provides higher
AODD pumps. The performance, lower
patent-pending EMS operational costs
is simple and easy and flexibility that
to use. With the exceeds previous
turn of an integrated industry standards.
AIR CONSUMPTION
$ $$
Turning the dial Each dial setting Pro-Flo X™ pumps Moving the dial When the air
changes the represents an are shipped from from setting 4 consumption
relationship entirely different the factory on causes a decrease decreases more
between air inlet flow curve setting 4, which in flow and an even than the flow
and exhaust is the highest greater decrease in rate, efficiency
porting. flow rate setting air consumption. is improved and
possible operating costs
are reduced.
WILDEN PUMP & ENGINEERING, LLC 10 PX1 Performance

HOW TO USE THIS EMS CURVE
Example 1
SETTING 4 PERFORMANCE CURVE EMS CURVE
Figure 1 Figure 2
0.58 flow multiplier
Example data point = 8.2 GPM Example data point =
0.48 air multiplier
This is an example showing how to determine flow rate and curve, draw vertical lines downward until
air consumption for your Pro-Flo X™ pump using the Efficien- reaching the bottom scale on the chart. This
cy Management System (EMS) curve and the performance
identifies the flow X Factor (in this case, 0.58)
curve. For this example we will be using 4.1 bar (60 psig) inlet
air pressure and 2.8 bar (40 psig) discharge pressure and EMS and air X Factor (in this case, 0.48).
setting 2.
Step 3: Calculating performance for specific EMS
Step 1: Identifying performance at setting 4. Locate setting. Multiply the flow rate (8.2 gpm)
the curve that represents the flow rate of the obtained in Step 1 by the flow X Factor multi-
pump with 4.1 bar (60 psig) air inlet pressure. plier (0.58) in Step 2 to determine the flow rate
Mark the point where this curve crosses the at EMS setting 2. Multiply the air consump-
horizontal line representing 2.8 bar (40 psig) tion (9.8 scfm) obtained in Step 1 by the air
discharge pressure. (Figure 1). After locating X Factor multiplier (0.48) in Step 2 to deter-
your performance point on the flow curve, mine the air consumption at EMS setting 2
draw a vertical line downward until reaching (Figure 3).
the bottom scale on the chart. Identify the flow
rate (in this case, 8.2 gpm). Observe location 8.2 gpm (flow rate for Setting 4)
of performance point relative to air consump-
tion curves and approximate air consumption
.58 (Flow X Factor setting 2)
value (in this case, 9.8 scfm). 4.8 gpm (Flow rate for setting 2)
Step 2: Determining flow and air X Factors. Locate 9.8 scfm (air consumption for setting 4)
your discharge pressure (40 psig) on the verti-
cal axis of the EMS curve (Figure 2). Follow
.48 (Air X Factor setting 2)
along the 2.8 bar (40 psig) horizontal line until 4.7 scfm (air consumption for setting 2)
intersecting both flow and air curves for your
Figure 3
desired EMS setting (in this case, setting 2).
Mark the points where the EMS curves inter- The flow rate and air consumption at Setting
sect the horizontal discharge pressure line. 2 are found to be 18.2 lpm (4.8 gpm) and 7.9
After locating your EMS points on the EMS Nm3/h (4.7 scfm) respectively.
PX1 Performance 11 WILDEN PUMP & ENGINEERING, LLC

Example 2.1
EMS Flow
Settings 1 & 2
Figure 4 Figure 5
Example data point = 10.2 gpm 0.49 flow multiplier
This is an example showing how to determine the inlet air In our example it is 38.6 lpm (10.2 gpm). This
pressure and the EMS setting for your Pro-Flo X™ pump to is the setting 4 flow rate. Observe the loca-
optimize the pump for a specific application. For this exam- tion of the performance point relative to air
ple we will be using an application requirement of 18.9 lpm
consumption curves and approximate air
(5 gpm) flow rate against 2.8 bar (40 psig) discharge pressure.
This example will illustrate how to calculate the air consump- consumption value. In our example setting
tion that could be expected at this operational point. 4 air consumption is 24 Nm3/h (14 scfm).
See figure 4.
DETERMINE EMS SETTING
Step 3: Determine flow X Factor. Divide the required
Step 1: Establish inlet air pressure. Higher air pres-
flow rate 18.9 lpm (5 gpm) by the setting 4 flow
sures will typically allow the pump to run
rate 38.6 lpm (10.2 gpm) to determine the flow
more efficiently, however, available plant air
X Factor for the application.
pressure can vary greatly. If an operating
pressure of 6.9 bar (100 psig) is chosen when 5 gpm / 10.2 gpm = 0.49 (flow X Factor)
plant air frequently dips to 6.2 bar (90 psig)
pump performance will vary. Choose an oper- Step 4: Determine EMS setting from the flow
ating pressure that is within your compressed X Factor. Plot the point representing the flow
air systems capabilities. For this example we X Factor (0.49) and the application discharge
will choose 4.1 bar (60 psig). pressure 2.8 bar (40 psig) on the EMS curve.
This is done by following the horizontal 2.8
Step 2: Determine performance point at setting 4. For bar (40 psig) psig discharge pressure line until
this example an inlet air pressure of 4.1 bar it crosses the vertical 0.49 X Factor line. Typi-
(60 psig) inlet air pressure has been chosen. cally, this point lies between two flow EMS
Locate the curve that represents the perfor- setting curves (in this case, the point lies be-
mance of the pump with 4.1 bar (60 psig) inlet tween the flow curves for EMS setting 1 and
air pressure. Mark the point where this curve 2). Observe the location of the point relative
crosses the horizontal line representing 2.8 to the two curves it lies between and approxi-
bar (40 psig) discharge pressure. After locat- mate the EMS setting (figure 5). For more pre-
ing this point on the flow curve, draw a verti- cise results you can mathematically interpo-
cal line downward until reaching the bottom late between the two curves to determine the
scale on the chart and identify the flow rate. optimal EMS setting.
For this example the EMS setting is 1.8.
WILDEN PUMP & ENGINEERING, LLC 12 PX1 Performance
Example 2.2
EMS Air
Settings 1 & 2
Figure 6 Figure 7
Example data point = 10.2 gpm Example data point = 0.40 air multiplier
Determine air consumption at a specific Step 2: Determine air consumption. Multiply your
EMS setting. setting 4 air consumption (14 scfm) value by
the air X Factor obtained above (0.40) to deter-
Step 1: Determine air X Factor. In order to determine mine your actual air consumption.
the air X Factor, identify the two air EMS set-
ting curves closest to the EMS setting estab- 14 scfm x 0.40 = 5.6 SCFM
lished in example 2.1 (in this case, the point lies
In summary, for an application requiring 18.9 lpm
between the air curves for EMS setting 1 and
(5 gpm) against 2.8 bar (40 psig) discharge pressure,
2). The point representing your EMS setting
the pump inlet air pressure should be set to 4.1 bar
(1.8) must be approximated and plotted on the
(60 psig) and the EMS dial should be set to 1.8. The
EMS curve along the horizontal line represent-
pump would then consume 9.5 Nm3/h (5.6 scfm) of
ing your discharge pressure (in this case, 40
compressed air.
psig). This air point is different than the flow
point plotted in example 2.1. After estimating
(or interpolating) this point on the curve, draw
a vertical line downward until reaching the
bottom scale on the chart and identify the air
X Factor (figure 7).
For this example the air X Factor is 0.40

PX1 METAL RUBBER-FITTED
WILDEN PUMP & ENGINEERING, LLC

PERFORMANCE
14
TECHNICAL DATA EXAMPLE
The Efficiency Management System (EMS)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . .224 mm (8.8”) can be used to optimize the performance of A PX1 metal, Rubber-fitted pump operating at EMS setting 4,
Width. . . . . . . . . . . . . . . . . . . . . . . . . . . .208 mm (8.2”) your Wilden pump for specific applications. achieved a flow rate of 56.8 lpm (15.0 gpm) using 35.7 Nm3/h (21.0
Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . .221 mm (8.7”) The pump is delivered with the EMS adjusted scfm) of air when run at 5.5 bar (80 psig) air inlet pressure and 1.4
Ship Weight . . . . . . . . . . . . . Aluminum 6 kg (13 lbs.) to setting 4, which allows maximum flow. bar (20 psig) discharge pressure (See dot on flow chart).
. . . . . . . . . . . . . . . . 316 Stainless Steel 9 kg (20 lbs.)
Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (1/2”) The EMS curve allows the pump user to deter- The end user did not require that much flow and wanted to reduce
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (1/2”) mine flow and air consumption at each EMS air consumption at his facility. He determined that EMS setting
Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (1/2”) setting. For any EMS setting and discharge 2 would meet his needs. At 1.4 bar (20 psig) discharge pressure
Suction Lift . . . . . . . . . . . . . . . . . . . . .5.9 m Dry (19.3’) pressure, the “X factor” is used as a multi- and EMS setting 2, the flow “X factor” is .66 and the air “X factor”
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 m Wet (26.1’) plier with the original values from the setting is .48.
Disp. Per Stroke. . . . . . . . . . . . . . . 0.09 l (0.023 gal.)1 4 performance curve to calculate the actual Multiplying the original setting 4 values by the “X factors” provides
Max. Flow Rate . . . . . . . . . . . . . .62.5 lpm (16.5 gpm) flow and air consumption values for that spe- the setting 2 flow rate of 37.5 lpm (9.9 gpm) and an air consump-
Max. Size Solids . . . . . . . . . . . . . . . . . 1.6 mm (1/16”) cific EMS setting. Note: you can interpolate tion of 17.2 Nm3/h (10.1 scfm). The flow rate was reduced by 34%
between the setting curves for operation at while the air consumption was reduced by 52%, thus providing
1
Displacement per stroke was calculated at 4.8 intermediate EMS settings.
bar (70 psig) air inlet pressure against a 2 bar increased efficiency.
(30 psig)head pressure. For a detailed example for how to set your EMS, see beginning of
performance curve section.
Caution: Do not exceed 8.6 bar (125 psig) air supply pressure.
PX1 Performance
PX1 METAL TPE-FITTED
PX1 Performance
PERFORMANCE
15
Height . . . . . . . . . . . . . . . . . . . . . . . . . . .224 mm (8.8”) can be used to optimize the performance of A PX1 metal, TPE-fitted pump operating at EMS setting 4, achieved
Width. . . . . . . . . . . . . . . . . . . . . . . . . . . .208 mm (8.2”) your Wilden pump for specific applications. a flow rate of 56.0 lpm (14.8 gpm) using 29.7 Nm3/h (17.5 scfm) of air
Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . .221 mm (8.7”) The pump is delivered with the EMS adjusted when run at 4.8 bar (70 psig) air inlet pressure and 0.7 bar (10 psig)
Ship Weight . . . . . . . . . . . . . Aluminum 6 kg (13 lbs.) to setting 4, which allows maximum flow. discharge pressure (See dot on flow chart).
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (1/2”) mine flow and air consumption at each EMS air consumption at his facility. He determined that EMS setting
Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (1/2”) setting. For any EMS setting and discharge 1 would meet his needs. At 0.7 bar (10 psig) discharge pressure
Suction Lift . . . . . . . . . . . . . . . . . . . . .5.7 m Dry (18.7’) pressure, the “X factor” is used as a multi- and EMS setting 1, the flow “X factor” is .32 and the air “X factor”
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 m Wet (30.6’) plier with the original values from the setting is .14.
Max. Flow Rate . . . . . . . . . . . . . .62.8 lpm (16.6 gpm) flow and air consumption values for that spe- the setting 1 flow rate of 17.8 lpm (4.7 gpm) and an air consumption
Max. Size Solids . . . . . . . . . . . . . . . . . 1.6 mm (1/16”) cific EMS setting. Note: you can interpolate of 4.2 Nm3/h (2.5 scfm). The flow rate was reduced by 68% while
between the setting curves for operation at the air consumption was reduced by 86%, thus providing increased
1Displacement per stroke was calculated at 4.8 intermediate EMS settings. efficiency.
bar (70 psig) air inlet pressure against a 2 bar

PX1 METAL PTFE-FITTED

PERFORMANCE
16
Height . . . . . . . . . . . . . . . . . . . . . . . . . . .224 mm (8.8”) can be used to optimize the performance of A PX1 metal, PTFE-fitted pump operating at EMS setting 4, achieved
Width. . . . . . . . . . . . . . . . . . . . . . . . . . . .208 mm (8.2”) your Wilden pump for specific applications. a flow rate of 18.9 lpm (5 gpm) using 8.83 Nm3/h (5.2 SCFM) of air
Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . .221 mm (8.7”) The pump is delivered with the EMS adjusted when run at 3.2 bar (47 psig) air inlet pressure and 2.8 bar (40 psig)
Ship Weight . . . . . . . . . . . . . Aluminum 6 kg (13 lbs.) to setting 4, which allows maximum flow. discharge pressure (See dot on flow chart).
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (1/2”) mine flow and air consumption at each EMS air consumption at his facility. He determined that EMS setting 3
Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (1/2”) setting. For any EMS setting and discharge would meet his needs. At 2.8 bar (40 psig) discharge pressure and
Suction Lift . . . . . . . . . . . . . . . . . . . . .4.7 m Dry (15.3’) pressure, the “X factor” is used as a multi- EMS setting 3, the flow “X factor” is .86 and the air “X factor” is
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 m Wet (26.1’) plier with the original values from the setting .76.
Max. Flow Rate . . . . . . . . . . . . . .60.9 lpm (16.1 gpm) flow and air consumption values for that spe- the setting 3 flow rate of 16.3 lpm (4.3 gpm) and an air consumption
Max. Size Solids . . . . . . . . . . . . . . . . . 1.6 mm (1/16”) cific EMS setting. Note: you can interpolate of 6.8 Nm3/h (4.0 scfm). The flow rate was reduced by 14% while
between the setting curves for operation at the air consumption was reduced by 24%, thus providing increased
1
Displacement per stroke was calculated at 4.8 intermediate EMS settings.
bar (70 psig) air inlet pressure against a 2 bar efficiency.
PX1 Performance
NOTES

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22069 Van Buren St. • Grand Terrace, CA 92313-5651

Tel 909-422-1730 • Fax 909-783-3440 • www.wildenx.com
Section 5C
SUCTION LIFT CURVE
P1 ME TA L
SUCTION LIFT CURVE

PX1 ME TA L
Suction lift curves are calibrated for pumps operating at 305 charge elbows, viscosity of pumping fluid, elevation (atmo-
m (1,000’) above sea level. This chart is meant to be a guide spheric pressure) and pipe friction loss all affect the amount
only. There are many variables which can affect your pump’s of suction lift your pump will attain.
operating characteristics. The number of intake and dis-

Section 6
SUGGES T ED INS TA L L AT ION
Wilden pumps are designed to meet the performance requirements PIPING: Final determination of the pump site should not be made
of even the most demanding pumping applications. They have until the piping challenges of each possible location have been
been designed and manufactured to the highest standards and are evaluated. The impact of current and future installations should be
available in a variety of liquid path materials to meet your chemical considered ahead of time to make sure that inadvertent restrictions
resistance needs. Refer to the performance section of this manual are not created for any remaining sites.
for an in-depth analysis of the performance characteristics of your
For U.L. listed pumps, all installation must conform with NFPA 30,
pump. Wilden offers the widest variety of elastomer options in the
NFPA 30A, and other applicable codes. All pipe connections are
industry to satisfy temperature, chemical compatibility, abrasion
to be made using U.L. classified gasoline-resistant pipe compound.
resistance and flex concerns.
Exhaust port is to be connected to pipe or tubing to be routed
The suction pipe size should be at least the equivalent or larger outdoors or other location determined to be equivalent.
than the diameter size of the suction inlet on your Wilden pump.
The best choice possible will be a site involving the shortest and
The suction hose must be non-collapsible, reinforced type as these
straightest hook-up of suction and discharge piping. Unnecessary
pumps are capable of pulling a high vacuum. Discharge piping
elbows, bends, and fittings should be avoided. Pipe sizes should
should also be the equivalent or larger than the diameter of the
be selected to keep friction losses within practical limits. All piping
pump discharge which will help reduce friction losses. It is critical
should be supported independently of the pump. In addition, the
that all fittings and connections are airtight or a reduction or loss of
piping should be aligned to avoid placing stress on the pump
pump suction capability will result.
fittings.
INSTALLATION: Months of careful planning, study, and selection
Flexible hose can be installed to aid in absorbing the forces created
efforts can result in unsatisfactory pump performance if installation
by the natural reciprocating action of the pump. If the pump is to be
details are left to chance.
bolted down to a solid location, a mounting pad placed between the
Premature failure and long term dissatisfaction can be avoided if pump and the foundation will assist in minimizing pump vibration.
reasonable care is exercised throughout the installation process. Flexible connections between the pump and rigid piping will also
assist in minimizing pump vibration. If quick-closing valves are
LOCATION: Noise, safety, and other logistical factors usually dictate
installed at any point in the discharge system, or if pulsation within
where equipment will be situated on the production floor. Multiple
a system becomes a problem, a surge suppressor (SD Equalizer®)
installations with conflicting requirements can result in congestion
should be installed to protect the pump, piping and gauges from
of utility areas, leaving few choices for additional pumps.
surges and water hammer.
Within the framework of these and other existing conditions, every
If the pump is to be used in a self-priming application, make sure
pump should be located in such a way that six key factors are
that all connections are airtight and that the suction lift is within
balanced against each other to maximum advantage.
the model’s ability. Note: Materials of construction and elastomer
ACCESS: First of all, the location should be accessible. If it’s easy material have an effect on suction lift parameters. Please refer to the
to reach the pump, maintenance personnel will have an easier time performance section for specifics.
carrying out routine inspections and adjustments. Should major
When pumps are installed in applications involving flooded suction
repairs become necessary, ease of access can play a key role in
or suction head pressures, a gate valve should be installed in the
speeding the repair process and reducing total downtime.
suction line to permit closing of the line for pump service.
AIR SUPPLY: Every pump location should have an air line large
Pumps in service with a positive suction head are most efficient
enough to supply the volume of air necessary to achieve the desired
when inlet pressure is limited to 0.5–0.7 bar (7–10 psig). Premature
pumping rate. Use air pressure up to a maximum of 8.6 bar (125
diaphragm failure may occur if positive suction is 0.7 bar (10 psig)
psig) depending on pumping requirements.
and higher.
For best results, the pumps should use a 5µ (micron) air filter,
SUBMERSIBLE APPLICATIONS: Pro-Flo X™ pumps can
needle valve and regulator. The use of an air filter before the pump
be used for submersible applications, when using the
will ensure that the majority of any pipeline contaminants will be
Pro-Flo X™ submersible option. Turbo-Flo™ pumps can also be
eliminated.
used for submersible applications.
NOTE: Canadian Standards Association (CSA) configured pumps
NOTE: Pro-Flo® and Accu-Flo™ pumps are not submersible.
should not exceed 6.9 bar (100 psig) sweet gas supply pressure.
ONLY CSA configured pumps should be operated using gas. ALL WILDEN PUMPS ARE CAPABLE OF PASSING SOLIDS. A
STRAINER SHOULD BE USED ON THE PUMP INTAKE TO ENSURE
SOLENOID OPERATION: When operation is controlled by a solenoid
THAT THE PUMP'S RATED SOLIDS CAPACITY IS NOT EXCEEDED.
valve in the air line, three-way valves should be used. This valve
allows trapped air between the valve and the pump to bleed off CAUTION: DO NOT EXCEED 8.6 BAR (125 PSIG) AIR SUPPLY
which improves pump performance. Pumping volume can be PRESSURE.
estimated by counting the number of strokes per minute and then
CAUTION: CANADIAN STANDARDS ASSOCIATION (CSA)
multiplying the figure by the displacement per stroke.
CONFIGURED PUMPS SHOULD NOT EXCEED 6.9 BAR (100 PSIG)
MUFFLER: Sound levels are reduced below OSHA specifications SWEET GAS SUPPLY PRESSURE.
using the standard Wilden muffler. Other mufflers can be used
CAUTION: FOR U.L. LISTED PUMPS, DO NOT EXCEED 3.4 BAR (50
to further reduce sound levels, but they usually reduce pump
PSIG) AIR SUPPLY PRESSURE.
performance.
ELEVATION: Selecting a site that is well within the pump’s dynamic
lift capability will assure that loss-of-prime issues will be eliminated.
In addition, pump efficiency can be adversely affected if proper
attention is not given to site location.

S U G G E S T E D I N S TA L L AT I O N
This illustration is a generic
representation of an air-operated
double-diaphragm pump.
NOTE: In the event of a power failure, the shut off valve shut off valve (user supplied) installed in the air supply
should be closed, if the restarting of the pump is not line. A properly functioning valve will stop the air supply
desirable once power is regained. to the pump, therefore stopping output. This shut off
valve should be located far enough away from the
AIR OPERATED PUMPS: To stop the pump from pumping equipment such that it can be reached safely
operating in an emergency situation, simply close the in an emergency situation.

S U G G E S T E D O P E R AT I O N & M A I N T E N A N C E
OPERATION: P1 and PX1 pumps are pre-lubricated, and The P1 and PX1 pumps run solely on compressed air
do not require in-line lubrication. Additional lubrication and do not generate heat, therefore your process fluid
will not damage the pump, however if the pump is temperature will not be affected.
heavily lubricated by an external source, the pump’s NOTE: Canadian StandardsAssociation (CSA) configured
internal lubrication may be washed away. If the pump is pumps run solely on gas and do not generate heat.
then moved to a non-lubricated location, it may need to
be disassembled and re-lubricated as described in the MAINTENANCE AND INSPECTIONS: Since each
ASSEMBLY/DISASSEMBLY INSTRUCTIONS. application is unique, maintenance schedules may be
different for every pump. Frequency of use, line pressure,
Pump discharge rate can be controlled by limiting the viscosity and abrasiveness of process fluid all affect
volume and/or pressure of the air supply to the pump. A the parts life of a Wilden pump. Periodic inspections
regulator is used to control air pressure while a needle have been found to offer the best means for preventing
valve is used to control volume. Pump discharge rate unscheduled pump downtime. Personnel familiar with
can also be controlled by throttling the pump discharge the pump’s construction and service should be informed
by partially closing a valve in the discharge line of the of any abnormalities that are detected during operation.
pump. This action increases friction loss which reduces
flow rate. (See Section 5.) This is useful when the need RECORDS: When service is required, a record should be
exists to control the pump from a remote location. made of all necessary repairs and replacements. Over
When the pump discharge pressure equals or exceeds a period of time, such records can become a valuable
the air supply pressure, the pump will stop; no bypass tool for predicting and preventing future maintenance
or pressure relief valve is needed, and pump damage problems and unscheduled downtime. In addition,
will not occur. The pump has reached a “deadhead” accurate records make it possible to identify pumps
situation and can be restarted by reducing the fluid that are poorly suited to their applications.
discharge pressure or increasing the air inlet pressure.
TROUBLESHOOTING
Pump will not run or runs slowly. 2. Verify that vacuum required to lift liquid is not
greater than the vapor pressure of the material
1. Ensure that the air inlet pressure is at least 0.3 Bar
being pumped (cavitation).
(5 psig) above startup pressure and that the differential
pressure (the difference between air inlet and liquid 3. Check for sticking ball check valves. If material being
discharge pressures) is not less than 0.7 Bar (10 psig). pumped is not compatible with pump elastomers,
swelling may occur. Replace ball check valves and
2. Check air inlet filter for debris (see recommended
seats with proper elastomers. Also, as the check
installation).
valve balls wear out, they become smaller and can
3. Check for extreme air leakage (blow by) which become stuck in the seats. In this case, replace balls
would indicate worn seals/bores in the air valve, and seats.
pilot spool, main shaft.
Pump air valve freezes.
4. Disassemble pump and check for obstructions
in the air passageways or objects which would 1. Check for excessive moisture in compressed
obstruct the movement of internal parts. air. Either install a dryer or hot air generator for
compressed air. Alternatively, a coalescing filter may
5. Check for sticking ball check valves. If material being be used to remove the water from the compressed
pumped is not compatible with pump elastomers, air in some applications.
swelling may occur. Replace ball check valves and
seals with proper elastomers. Also, as the check Air bubbles in pump discharge.
valve balls wear out, they become smaller and can 1. Check for ruptured diaphragm.
become stuck in the seats. In this case, replace balls
and seats. 2. Check tightness of outer pistons (refer to Section 7).
6. Check for broken inner piston which will cause the 3. Check tightness of fasteners and integrity of
air valve spool to be unable to shift. o-rings and seals, especially at intake manifold.
7. Remove plug from pilot spool exhaust. 4. Ensure pipe connections are airtight.
Pump runs but little or no product flows. Product comes out air exhaust.
1. Check for pump cavitation; slow pump speed down 1. Check for diaphragm rupture.
to allow thick material to flow into liquid chambers. 2. Check tightness of outer pistons to shaft.
Section 7
P U M P DIS A S SE M BLY
P1 M ETA L
TOOLS REQUIRED: CAUTION: Before any maintenance or repair is attempted, the compressed air line
• 3/8" Box Wrench to the pump should be disconnected and all air pressure allowed to bleed from the
• 7/16" Wrench pump. Disconnect all intake, discharge, and air lines. Drain the pump by turning it
• Adjustable Wrench upside down and allowing any fluid to flow into a suitable container. Be aware of
• Vise equipped with soft any hazardous effects of contact with your process fluid.
jaws (such as plywood, NOTE: The model photographed for these instructions is a Pro-FloX™ version and
plastic or other suitable incorporates rubber diaphragms, balls, and seats.
material)
Step 1 Step 2 Step 3

Prior to disassembly, alignment Using a 7/16" box wrench, remove Next, remove the discharge manifold
marks should be placed on the the nuts that connect the inlet and from the pump.
liquid chambers and air chamber to discharge manifolds to the center
assist with proper alignment during section assembly.
reassembly.

P U M P D I S A S S E M B LY

Remove the discharge valve ball, Now the center section assembly Remove the inlet valve ball, valve
valve seat and valve seat o-ring can be removed from the inlet seat and valve seat o-ring and inspect
and inspect for signs of wear and manifold. for signs of wear and/or chemical
replace if necessary. attack. Replace if necessary.

Using a 3/8" wrench, remove the Remove the tee section o-rings Using a 7/16" box end wrench,
small clamp band that connects the and inspect for signs of wear and/ remove the large clamp bands.
manifold elbows to the tee section. or chemical attack. Replace if With the clamp bands removed, lift
necessary. the liquid chamber away from the
center section.

P U M P D I S A S S E M B LY
Step 10 Step 11A Step 11B

Using an adjustable wrench or Due to varying torque values, one B) The diaphragm assembly and
rotating the diaphragm by hand, of the two situations will occur: shaft remain connected leaving
remove the diaphragm assembly A) The outer piston, diaphragm the opposite side diaphragm
from the center section. and inner piston will separate assembly within the opposite
from the shaft which remains side of the center section
connected to the opposite side assembly.
diaphragm assembly.
GROUNDING STRAP FOR CSA PX1 PUMPS
Figure 1 Figure 2
Step 12
Canadian Standards Association (CSA) configured pumps must be
To remove the diaphragm assembly electrically grounded using the grounding strap provided (Figure 1).
from the shaft, secure shaft with Improper grounding can cause improper and dangerous operation. To
soft jaws (a vise fitted with plywood properly attach the grounding strap to a CSA convfigured PX1 pump,
or other suitable material) to ensure identify the designated grounding location on the muffler plate; using the
shaft is not nicked, scratched, provided self-tapping screw and grounding wire, thread the grounding
or gouged. Using an adjustable screw through the grounding wire lug, into the muffler plate and tighten
wrench, remove the diaphragm securely (figure 2). Completion of the pump grounding procedure must
assembly from shaft. Inspect all be done in accordance with local codes, or in the absence of local codes,
parts for wear and replace with an industrial or nationally recognized code having jurisdiction over the
genuine Wilden parts if necessary. specified installation.

A I R VA LV E / C E N T E R S E C T I O N D I S A S S E M B LY
TOOLS REQUIRED: CAUTION: Before any maintenance or repair is attempted, the compressed air line
to the pump should be disconnected and all air pressure allowed to bleed from the
• 3/16" Hex Head Wrench pump. Disconnect all intake, discharge, and air lines. Drain the pump by turning it
• 7/32" Hex Head Wrench upside down and allowing any fluid to flow into a suitable container. Be aware of
• Snap Ring Pliers hazardous effects of contact with your process fluid.
• O-Ring Pick

Using a 3/16” hex head wrench, Remove the air valve and muffler Remove the air valve gasket
loosen the air valve bolts. plate from the center section. and inspet for nicks, gouges and
chemical attack. Replace if necessary
with genuine Wilden parts. Note:
When installing the air valve gasket
onto the center section assembly,
position gasket with the grooved
side facing away from the center
section.


Remove muffler plate gasket and Remove air valve end cap to expose Remove air valve spool from air
inspect. Replace if necessary. air valve spool. NOTE: The end cap valve body by threading one air valve
cannot be removed until removing bolt into the end of the spool and
air valve bolts. gently sliding the spool out of the air
valve body. Inspect seals for signs of
wear and replace entire assembly if
necessary. Use caution when handling
air valve spool to prevent damaging
seals. NOTE: Seals should not be
removed from assembly. Seals are not
sold separately.

Remove pilot spool retaining snap Remove pilot spool assembly from Using an o-ring pick, gently
ring on both sides of center section center section. remove the pilot spool retaining
with snap ring pliers. o-ring from the opposite side of the notched
end of the spool. Gently remove the pilot
spool from pilot spool sleeve and inspect
for nicks, gouges and other signs of wear.
Replace pilot spool assembly or outer sleeve
o-rings if necessary. During re-assembly
never insert the pilot spool into the sleeve
with the “notched” end side first, this end
incorporates the urethane o-ring and will be
damaged as it slides over the ports cut in
the pilot spool sleeve.
Step 10
Check center section shaft seals
for signs of wear. If necessary,
remove the shaft seals with an
o-ring pick and replace.
SUBMERSIBLE PRO-FLO X™
Non-Submersible Submersible
Step 1 Step 2
Install a 1/4" NPT pipe plug (00-7010- Next, install an optional submersible air valve gasket (01-2621-
08) into the pilot spool bleed port 52). The submersible air valve gasket can be purchased as a
located at the front of the center spare part or included with the purchase of a new Pro-Flo X™
section. pump.

R E A S S E M B LY H I N T & T I P S
ASSEMBLY:
Upon performing applicable maintenance to the air distribu- • Level the water chamber side of the intake/discharge
tion system, the pump can now be reassembled. Please manifold to ensure a proper sealing surface. This is most
refer to the disassembly instructions for photos and parts easily accomplished by placing them on a flat surface
placement. To reassemble the pump, follow the disassembly prior to tightening their clamp bands to the desired torque
instructions in reverse order. The air distribution system needs (see this page for torque specs).
to be assembled first, then the diaphragms and finally the • Be sure to tighten outer pistons simultaneously on PTFE-
wetted path. Please find the applicable torque specifications
fitted pumps to ensure proper torque values.
on this page. The following tips will assist in the assembly
process. • Ensure proper mating of liquid chambers to manifolds
prior to tightening vertical bolts. Overhang should be
• Clean the inside of the center section shaft bore to ensure equal on both sides.
no damage is done to new seals. • Apply a small amount of Loctite 242 to the shaft interval
• Stainless bolts should be lubed to reduce the possibility of threads before the diaphragm assembly.
seizing during tightening. • Concave side of disc spring in diaphragm assembly faces
toward shaft.
PRO-FLO® MAXIMUM TORQUE SPECIFICATIONS PRO-FLO X™ MAXIMUM TORQUE SPECIFICATIONS

Description of Part Maximum Torque Description of Part Maximum Torque
Air Valve, Pro-Flo® 3.1 N•m (27 in-lbs.) Air Valve, Pro-Flo X™ 11.3 N•m (100 in-lbs.)
Outer Piston 14.1 N•m (125 in) Outer Piston 14.1 N•m (125 in)
Small Clamp Band 1.7 N•m (15 in) Small Clamp Band 1.7 N•m (15 in)
Large Clamp Band (Rubber/TPE-Fitted) 9.0 N•m (80 in) Large Clamp Band (Rubber/TPE-Fitted) 9.0 N•m (80 in)
Large Clamp Band (PTFE-Fitted) 13.6 N•m (120 in) Large Clamp Band (PTFE-Fitted) 13.6 N•m (120 in)
Vertical Bolts 14.1 N•m (125 in) Vertical Bolts 14.1 N•m (125 in)
E L A S T O M E R K I T S
Program Details:
• Elastomer & ADS Repair Kits • Eliminates Order Errors

• All Sizes Available • Reduces Re-Build Time
• PTFE, Rubber & TPE Elastomers • Rejuvenates Your Pump
• One Part Number Simplifies Inventory
NOTE: See Section 9.

Section 8
E XPLODED VIE W & PARTS LISTING
P1 METAL RUBBER/ TPE-FITTED EXPLODED VIEW

P1 METAL RUBBER/ TPE-FITTED PA R T S L I S T I N G
Qty. Per P1/APPP P1/SPPP P1/SPPP/070

Item Part Description Pump P/N P/N P/N
1 Pro-Flo™ Air Valve Assembly 1
1 01-2010-20 01-2010-20 01-2010-20
2 End Cap 1 01-2332-20 01-2332-20 01-2332-20
3 O-Ring (-126), End Cap (Ø.1.362 x Ø.103) 1 01-2395-52 01-2395-52 01-2395-52
4 Gasket, Air Valve 1 01-2615-52 01-2615-52 01-2615-52
5 Screw, HSHC, Air Valve (1/4"-20 x 3") 4 01-6001-03 01-6001-03 01-6001-03
6 Nut, Hex, (1/4”-20) 4 04-6400-03 04-6400-03 04-6400-03
7 Center Section Assembly 1 01-3140-20 01-3140-20 01-3140-20
8 Bushing, Reducer 1 01-6950-20 01-6950-20 01-6950-20
9 Removable Pilot Sleeve Assembly 1 01-3880-99 01-3880-99 01-3880-99
10 Shaft Seal 2 01-3220-55 01-3220-55 01-3220-55
11 Retaining Ring 2 00-2650-03 00-2650-03 00-2650-03
12 Muffler Plate 1 01-3181-20 01-3181-20 01-3181-20
13 Gasket, Muffler Plate 1 01-3505-52 01-3505-52 01-3505-52
14 Muffler 1 02-3510-99 02-3510-99 02-3510-99
15 Shaft, Pro-Flo™ 1 01-3810-03 01-3810-03 01-3810-03
16 Disc Spring 2 01-6802-08 01-6802-08 01-6802-08
17 Inner Piston 2 01-3711-08 01-3711-08 01-3711-08
18 Outer Piston 2 01-4570-01 01-4570-03 01-4570-03
19 Liquid Chamber 2 01-5000-01 01-5000-03 01-5000-03
20 Manifold Tee Section 2 01-5160-01 01-5160-03 01-5160-03-70
21 Inlet Manifold Elbow 2 01-5220-01 01-5220-03 01-5220-03
22 Discharge Manifold Elbow 2 01-5230-01 01-5230-03 01-5230-03
23 Screw, SHCS (Chamber Bolt) (1/4"-20 x 7 3/8) 4 01-6080-03 01-6080-03 01-6080-03
24 Vertical Bolt Washer (.2811.D. x .6250.D. x .065THR) 4 01-6730-03 01-6730-03 01-6730-03
25 Vertical Bolt Nut (1/4"-20) 4 04-6400-03 04-6400-03 04-6650-03-70
26 Diaphragm 2 * * 01-1010-56
27 Valve Ball 4 * * 01-1080-56
28 Valve Seat 4 01-1120-01 01-1120-03 01-1120-03P
29 Valve Seat O-Ring 4 * * 01-1200-56
30 Manifold O-Ring (Ø.987 x Ø.103) 4 * * 01-1300-56
31 Small Clamp Band Assy. 4 01-7100-03 01-7100-03 01-7100-03P
32 Small Clamp Band Bolt 8 01-6101-03 01-6101-03 01-6101-03
33 Small Clamp Band Nut (#10-24) 8 01-6400-03 01-6400-03 01-6400-03
34 Large Clamp Band Assy. 2 01-7300-03 01-7300-03 01-7300-03
35 Large Clamp Band Bolt (1/4"-20 x 2 1/4") 4 01-6070-03 01-6070-03 01-6070-03
36 Large Clamp Band Nut (1/4"-20) 4 04-6400-03 04-6400-03 04-6650-03-70
Wing Nut (Not Shown) 4 N/A N/A 04-6651-10
1
Air Valve Assembly includes items 2 and 3.
*Refer to corresponding elastomer chart in Section 10.
070 Specialty Code = SanifloFDA
All boldface items are primary wear parts.

P1 METAL PTFE-FITTED EXPLODED VIEW

P1 METAL PTFE-FITTED PA R T S L I S T I N G
Qty Per. P1/APPP P1/SPPP P1/SPPP/070

Item Part Description Pump P/N P/N P/N
1 Pro-Flo™ Air Valve Assembly 1
1 01-2010-20 01-2010-20 01-2010-20
2 End Cap 1 01-2332-20 01-2332-20 01-2332-20
3 O-Ring (-126) (Ø.1.362 x Ø.103), End Cap 1 01-2395-52 01-2395-52 01-2395-52
4 Gasket, Air Valve 1 01-2615-52 01-2615-52 01-2615-52
5 Screw, HSHC, Air Valve (1⁄4-20 x 3") 4 01-6001-03 01-6001-03 01-6001-03
6 Nut, Hex, (1/4”-20) 4 04-6400-03 04-6400-03 04-6400-03
7 Center Section Assembly 1 01-3140-20 01-3140-20 01-3140-20
8 Bushing, Reducer 1 01-6950-20 01-6950-20 01-6950-20
9 Removable Pilot Sleeve Assembly 1 01-3880-99 01-3880-99 01-3880-99
10 Shaft Seal 2 01-3220-55 01-3220-55 01-3220-55
11 Retaining Ring 2 00-2650-03 00-2650-03 00-2650-03
12 Muffler Plate 1 01-3181-20 01-3181-20 01-3181-20
13 Gasket, Muffler Plate 1 01-3505-52 01-3505-52 01-3505-52
14 Muffler 1 02-3510-99 02-3510-99 01-3510-99
15 Shaft, Pro-Flo™ 1 01-3810-03 01-3810-03 01-3810-03
16 Disc Spring (Belleville Washer) 2 01-6802-08 01-6802-08 01-6802-08
17 Inner Piston 2 01-3711-08 01-3711-08 01-3711-08
18 Outer Piston 2 01-4570-01 01-4570-03 01-4570-03
19 Liquid Chamber 2 01-5000-01 01-5000-03 01-5000-03
20 Manifold Tee Section 2 01-5160-01 01-5160-03 01-5160-03-70
21 Inlet Manifold Elbow 2 01-5220-01 01-5220-03 01-5220-03
22 Discharge Manifold Elbow 2 01-5230-01 01-5230-03 01-5230-03
23 Screw, SHCS (Chamber Bolt) (1/4"-20 x 7 3/8) 4 01-6080-03 01-6080-03 01-6080-03
24 Vertical Bolt Washer (.2811.D. x .6250.D. x .065THR) 4 01-6730-03 01-6730-03 01-6730-03
25 Vertical Bolt Nut (1/4"-20) 4 04-6400-03 04-6400-03 04-6650-03-70
26 PTFE Primary Diaphragm 2 01-1010-55 01-1010-55 01-1010-55
27 Neoprene Backup Diaphragm 2 01-1060-51 01-1060-51 01-1060-51
28 Valve Ball 4 01-1080-55 01-1080-55 01-1080-55
29 Valve Seat 4 01-1120-01 01-1120-03 01-1120-03P
30 Valve Seat (-119) O-Ring (Ø.924 x Ø.103) 4 01-1200-55 01-1200-55 01-1200-55
31 Manifold (-120) O-Ring (Ø.987 x Ø.103) 4 01-1300-55 01-1300-55 01-1300-55
32 Small Clamp Band Assy. 4 01-7100-03 01-7100-03 01-7100-03
33 Small Clamp Band Bolt (#10-24 x 1") 8 01-6101-03 01-6101-03 01-6101-03
34 Small Clamp Band Nut (#10-24) 8 01-6400-03 01-6400-03 01-6400-03
35 Large Clamp Band Assy. 2 01-7300-03 01-7300-03 01-7300-03
36 Large Clamp Band Bolt (1/4"-20 x 2 1/4") 4 01-6070-03 01-6070-03 01-6070-03
37 Large Clamp Band Nut (1/4"-20) 4 04-6400-03 04-6400-03 04-6650-03-70
Wing Nut 4 N/A N/A 04-6651-10
1Air Valve Assembly includes items 2 and 3.
*Refer to corresponding elastomer chart in Section 10.
All boldface items are primary wear parts.

Section 9D
PX1 METAL RUBBER-FITTED EXPLODED VIEW
ALL CIRCLED PART IDENTIFIERS ARE INCLUDED IN REPAIR KITS.

PX1 METAL RUBBER-FITTED PA R T S L I S T I N G
PX1/AAAAA PX1/SSAAA PX1/SSNNN/0070

No. Part Description Qty P/N P/N P/N
1 Pro-Flo X® Air Valve Assembly1 1 01-2030-01 01-2030-01 01-2030-06
2 End Cap 1 01-2340-01 01-2340-01 01-2340-06
3 O-Ring (-126), End Cap (Ø1.362 x Ø.103) 1 01-2395-52 01-2395-52 01-2395-52
4 Gasket, Air Valve, Pro-Flo X® 1 01-2620-52 01-2620-52 01-2620-52
5 Gasket, Muffler Plate, Pro-Flo X® 1 01-3502-52 01-3502-52 01-3502-52
6 Muffler Plate, Pro-Flo X® 1 01-3185-01 01-3185-01 01-3185-06
7 Screw, SHC, Air Valve (1/4”-20 x 3”) 4 01-6001-03 01-6001-03 01-6001-03
8 Muffler* 1 02-3512-99 02-3512-99 02-3512-99
9 Center Section Assembly, Pro-Flo X® 2 1 01-3147-01 01-3147-01 01-3147-06
10 O-Ring (-206), Air Adjustment Pin (Ø.484 x Ø.139) 1 00-1300-52 00-1300-52 00-1300-52
11 Screw, 10-32 x .50 Self-Tapping Grounding 1 04-6345-08 04-6345-08 04-6345-08
12 Shaft Seal 2 01-3220-55 01-3220-55 01-3220-55
13 Pilot Sleeve Assembly 1 01-3880-99 01-3880-99 01-3880-99
14 Pilot Spool Retaining O-Ring 2 04-2650-49-700 04-2650-49-700 04-2650-49-700
15 Retaining Ring 1 00-2650-03 00-2650-03 00-2650-03
16 Shaft 1 01-3810-03 01-3810-03 01-3810-03
17 Stud, 5/16”-18 x 1 3/8” (not shown) 2 N/A N/A 01-6150-03
18 Disc Spring 2 01-6802-08 01-6802-08 01-6802-08
19 Inner Piston 2 01-3711-08 01-3711-08 01-3711-08
20 Diaphragm 2 * * 01-1010-56
21 Outer Piston 1 01-4570-01 01-4570-03 01-4570-03P
22 Liquid Chamber 2 01-5000-01 01-5000-03 01-5000-03P
23 Inlet Manifold Elbow 2 01-5220-01 01-5220-03 01-5220-03P
24 Manifold Tee Section 2 01-5160-01 01-5160-03 01-5160-03-70P
25 Discharge Manifold Elbow 2 01-5230-01 01-5230-03 01-5230-03P
26 Ball, Valve 4 * * 01-1080-56
27 Seat, Valve 4 01-1120-01 01-1120-03 01-1120-03P
28 Valve Seat (-119) O-Ring (Ø.924 x Ø.103) 4 * * 01-1200-56
29 Bolt, Carriage (1/4”-20 x 7-3/8”) 4 01-6080-03 01-6080-03 01-6080-03
30 Washer (1/4”) 4 01-6730-03 01-6730-03 01-6730-03
31 Hex Nut (1/4”-20) 4 04-6400-03 04-6400-03 04-6651-10
32 O-Ring (-120), Manifold (Ø.987 x Ø.103) 4 * * 01-1300-56
33 Large Clamp Band 4 01-7300-03 01-7300-03 01-7300-03
34 Bolt, Carriage (1/4”-20 x 2 1/4”) 4 01-6070-03 01-6070-03 01-6070-03
35 Hex Nut (1/4”-20) 4 04-6400-03 04-6400-03 N/A
36 Small Clamp Band 8 01-7100-03 01-7100-03 01-7100-03
37 Screw, HHC (#10-24 x 1”) 8 01-6101-03 01-6101-03 01-6101-03
38 Hex Nut (#10-24) 8 01-6400-03 01-6400-03 01-6400-03
39 Grounding Strap, CSA3 1 01-8303-99 01-8303-99 N/A
Wing Nut (not shown) 4 N/A N/A 04-6651-10
1
Air Valve Assembly includeds item numbers 2 and 3.
2
Center Section Assembly includes items 6, 10 and 12.
3
CSA pumps to use grounding strap.
For submersible Pro-Flo X™ pump, use air valve gasket 01-2621-52 and pipe plug 00-7010-08 or 00-7010-03.
0070 Specialty Code = SanifloFDAv
All boldface items are primary wear items
*NOTE: Muffler should not be used with Canadian Standards Association (CSA) pumps. The gas outlet of CSA configured
pumps must be vented to a safe location in accordance with local or, in the Absence of local codes, an industry or
nationally recognized code having jurisdiction over the specified installation.

PX1 METAL PTFE-FITTED EXPLODED VIEW
ALL CIRCLED PART IDENTIFIERS ARE INCLUDED IN REPAIR KITS.

PX1 METAL PTFE-FITTED PA R T S L I S T I N G
PX1/AAAAA PX1/SSAAA PX1/SSNNN/0070

No. Part Description Qty P/N P/N P/N
1 Pro-Flo X® Air Valve Assembly1 1 01-2030-01 01-2030-01 01-2030-06
2 End Cap 1 01-2340-01 01-2340-01 01-2340-06
3 O-Ring (-126), End Cap (Ø1.362 x Ø.103) 1 01-2395-52 01-2395-52 01-2395-52
4 Gasket, Air Valve, Pro-Flo X® 1 01-2620-52 01-2620-52 01-2620-52
5 Gasket, Muffler Plate, Pro-Flo X® 1 01-3502-52 01-3502-52 01-3502-52
6 Muffler Plate, Pro-Flo X® 1 01-3185-01 01-3185-01 01-3185-06
7 Screw, SHC, Air Valve (1/4”-20 x 3”) 4 01-6001-03 01-6001-03 01-6001-03
8 Muffler* 1 02-3512-99 02-3512-99 02-3512-99
9 Center Section Assembly, Pro-Flo X® 2 1 01-3147-01 01-3147-01 01-3147-06
10 O-Ring (-206), Air Adjustment Pin (Ø.484 x Ø.139) 1 00-1300-52 00-1300-52 00-1300-52
11 Screw, 10-32 x .50 Self-Tapping Grounding 1 04-6345-08 04-6345-08 04-6345-08
12 Shaft Seal 2 01-3220-55 01-3220-55 01-3220-55
13 Pilot Sleeve Assembly 1 01-3880-99 01-3880-99 01-3880-99
14 Pilot Spool Retaining O-Ring 2 04-2650-49-700 04-2650-49-700 04-2650-49-700
15 Retaining Ring 1 00-2650-03 00-2650-03 00-2650-03
16 Shaft 1 01-3810-03 01-3810-03 01-3810-03
17 Stud, 5/16” x 18 x 1 3/8” (not shown) 2 N/A N/A 01-6150-03
18 Disc Spring 2 01-6802-08 01-6802-08 01-6802-08
19 Inner Piston 2 01-3711-08 01-3711-08 01-3711-08
20 Diaphragm, Backup 2 01-1060-51 01-1060-51 01-1060-51
21 Diaphragm, Primary 2 01-1010-55 01-1010-55 01-1010-55
22 Outer Piston 1 01-4570-01 01-4570-03 01-4570-03P
23 Liquid Chamber 2 01-5000-01 01-5000-03 01-5000-03P
24 Inlet Manifold Elbow 2 01-5220-01 01-5220-03 01-5220-03P
25 Manifold Tee Section 2 01-5160-01 01-5160-03 01-5160-03-70P
26 Discharge Manifold Elbow 2 01-5230-01 01-5230-03 01-5230-03P
27 Ball, Valve 4 01-1080-56 01-1080-56 01-1080-56
28 Seat, Valve 4 01-1120-01 01-1120-03 01-1120-03P
29 Valve Seat (-119) O-Ring (Ø.924 x Ø.103) 4 01-1200-55 01-1200-55 01-1200-55
30 Bolt, Carriage (1/4”-20 x 7-3/8”) 4 01-6080-03 01-6080-03 01-6080-03
31 Washer (1/4”) 4 01-6730-03 01-6730-03 01-6730-03
32 Hex Nut (1/4”-20) 4 04-6400-03 04-6400-03 04-6651-10
33 O-Ring (-120), Manifold (Ø.987 x Ø.103) 4 01-1300-55 01-1300-55 01-1300-55
34 Large Clamp Band 4 01-7300-03 01-7300-03 01-7300-03
35 Bolt, Carriage (1/4”-20 x 2 1/4”) 4 01-6070-03 01-6070-03 01-6070-03
36 Hex Nut (1/4”-20) 4 04-6400-03 04-6400-03 N/A
37 Small Clamp Band 8 01-7100-03 01-7100-03 01-7100-03
38 Screw, HHC (#10-24 x 1”) 8 01-6101-03 01-6101-03 01-6101-03
39 Hex Nut (#10-24) 8 01-6400-03 01-6400-03 01-6400-03
40 Grounding Stap, CSA3 1 01-8303-99 01-8303-99 N/A
Wing Nut (not shown) 4 N/A N/A 04-6651-10
1
Air Valve Assembly includeds item numbers 2 and 3.
2
Center Section Assembly includes items 6, 10 and 12.
3
CSA pumps to use grounding strap.
For submersible Pro-Flo X™ pump, use air valve gasket 01-2621-52 and pipe plug 00-7010-08 or 00-7010-03.
All boldface items are primary wear items
*NOTE: Muffler should not be used with Canadian Standards Association (CSA) pumps. The gas outlet of CSA configured
pumps must be vented to a safe location in accordance with local or, in the Absence of local codes, an industry or
nationally recognized code having jurisdiction over the specified installation.

Section 9
ELASTOMER OPTIONS
P1 & PX1 Metal Pumps

Diaphragm VALVE BALL VALVE SEAT O-RING MANIFOLD O-RING
MATERIAL P/N P/N P/N P/N
Polyurethane 01-1010-50 01-1080-50 01-1200-50 01-1300-50
Buna-N 01-1010-52 01-1080-52 00-1260-52 01-1300-52
Viton® 01-1010-53 01-1080-53 N/A N/A
Wil-Flex™ 01-1010-58 01-1080-58 00-1260-58 00-1260-58
Saniflex™ 01-1010-56 01-1080-56 01-1200-56 01-1300-56
PTFE** 01-1010-55 01-1080-55 01-1200-55 01-1300-55
EPDM 01-1010-54 01-1080-54 00-1260-54 01-1300-54
**NOTE: An integral piston PTFE diaphragm is also available. To order this diaphragm, use part number 01-1030-55.
When using this diaphragm, no inner pistons are needed. The inner piston is integrated into the diaphragm design.

NOTES
NOTES
WARR ANT Y
Each and every product manufactured by Wilden Pump and Engineering, LLC is built to meet the highest
standards of quality. Every pump is functionally tested to insure integrity of operation.
Wilden Pump and Engineering, LLC warrants that pumps, accessories and parts manufactured or supplied by
it to be free from defects in material and workmanship for a period of five (5) years from date of installation or
six (6) years from date of manufacture, whichever comes first. Failure due to normal wear, misapplication, or
abuse is, of course, excluded from this warranty.
Since the use of Wilden pumps and parts is beyond our control, we cannot guarantee the suitability of any pump
or part for a particular application and Wilden Pump and Engineering, LLC shall not be liable for any consequential
damage or expense arising from the use or misuse of its products on any application. Responsibility is limited
solely to replacement or repair of defective Wilden pumps and parts.
All decisions as to the cause of failure are the sole determination of Wilden Pump and Engineering, LLC.
Prior approval must be obtained from Wilden for return of any items for warranty consideration and must be
accompanied by the appropriate MSDS for the product(s) involved. A Return Goods Tag, obtained from an
authorized Wilden distributor, must be included with the items which must be shipped freight prepaid.
The foregoing warranty is exclusive and in lieu of all other warranties expressed or implied (whether written or oral)
including all implied warranties of merchantability and fitness for any particular purpose. No distributor or other
person is authorized to assume any liability or obligation for Wilden Pump and Engineering, LLC other than expressly
provided herein.
PLEASE PRINT OR TYPE AND FAX TO WILDEN
P U M P I N F O R M AT I O N
Item # Serial #
Company Where Purchased
Y O U R I N F O R M AT I O N
Company Name
Industry
Name Title
Street Address
City State Postal Code Country
Telephone Fax E-mail Web Address
Number of pumps in facility? Number of Wilden pumps?
Types of pumps in facility (check all that apply): Diaphragm Centrifugal Gear Submersible Lobe
Other
Media being pumped?
How did you hear of Wilden Pump? Trade Journal Trade Show Internet/E-mail Distributor
Other
ONCE COMPLETE, FAX TO (909) 783-3440

NOTE: WARRANTY VOID IF PAGE IS NOT FAXED TO WILDEN
Translation of the original assembly instructions BA2-0NNN-112
Assembly and maintenance instructions for gear pumps and units AN-ZU: 05
Prep.: Web/15.03.10
Series R25, R35, R45, R65, R95 Checked: Lü/31.03.10
Name / Date
English Page 1 (32)
Form 229589-7
Prep.: Web/15.03.10
Name / Date
English Page 2 (32)
Contents Page
1 General Information ............................................................................................................4

1.1 Important General Information....................................................................................4
1.2 Warnings and Symbols ..............................................................................................5
1.3 Basic Safety Rules .....................................................................................................6
2 Technical data ....................................................................................................................6
2.1 Intended use...............................................................................................................6
2.2 Non-designated use ...................................................................................................7
2.3 Flow medium ..............................................................................................................8
2.4 Sound pressure level..................................................................................................9
3 Description..........................................................................................................................9
3.1 Pressure relief valve................................................................................................. 10
3.2 Using pressure relief valve R25, R35 DB (if installed) .............................................. 10
4 Transport and storage ...................................................................................................... 12
4.1 Storage and preservation ......................................................................................... 12
4.2 Lifting the gear pump or pump unit........................................................................... 13
5 Set-up / Mounting and Connection ................................................................................... 14
5.1 Set-up / Mounting ..................................................................................................... 14
5.1.1 Preparation...........................................................................................................14
5.1.2 Clutch alignment .................................................................................................. 15
5.1.3 Motor mounting .................................................................................................... 15
5.2 Planning and connection of pipes............................................................................. 16
5.2.1 Suction pipe design, NPSHR value...................................................................... 16
5.2.2 Connection of pipes ............................................................................................. 17
5.3 Electrical connection ................................................................................................ 18
6 Commissioning ................................................................................................................. 18
6.1 Before commissioning .............................................................................................. 18
6.2 Dry running............................................................................................................... 19
6.3 Direction of rotation .................................................................................................. 20
6.3.1 Checking the direction of rotation......................................................................... 20
6.3.2 Reversing the direction of rotation........................................................................ 21
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English Page 3 (32)
6.4 Commissioning......................................................................................................... 22
6.5 Recommissioning..................................................................................................... 23
7 Dismantling....................................................................................................................... 23
8 Maintenance / Service ...................................................................................................... 24
8.1 Gear pump ............................................................................................................... 24
8.2 Pump unit................................................................................................................. 25
9 Conversion / Changes ...................................................................................................... 26
10 Decommissioning ............................................................................................................. 26
11 Malfunctions / Causes / Remedies ................................................................................... 26
Illustrations
Figure 1: Gear pump delivery principle ..................................................................................... 9
Figure 2: Pressure relief valve R25 DB ................................................................................... 10
Figure 3: Pressure relief valve R35 DB ................................................................................... 10
Figure 4: Transport / Lifting ..................................................................................................... 13
Figure 5: NPSHR .................................................................................................................... 16
Figure 6: Direction of rotation .................................................................................................. 20
List of tables
Table 1: Warnings and consequences of non-observance ...................................................... 5
Table 2: Symbols and their meaning........................................................................................ 5
Table 3: Consequences of non-designated use....................................................................... 8
Table 4: Flow medium.............................................................................................................. 8
Table 5: Sound pressure level ................................................................................................. 9
Table 6: Tightening torques for pressure relief valves ........................................................... 11
Table 7: Tightening torques for brackets................................................................................ 15
Table 8: Maintenance of pump units ...................................................................................... 25
Table 9: Troubleshooting ....................................................................................................... 32
Form 229589-7
Prep.: Web/15.03.10
Name / Date
English Page 4 (32)
1 General Information
1.1 Important General Information

In addition to the information given in these assembly instructions, the acceptance of order and
the technical documentation must also be strictly observed.
The following documents must also be strictly observed:
→ Pump unit without drive motor: clutch operating manual.
→ Pump unit with drive motor: motor operating manual.
→ Other manuals.
→ For operation in a potentially explosive environment the ATEX operating manual
BA2-0NNN-113 supplied by Rickmeier GmbH must also be observed. The information in
that manual on operation of the gear pump supersedes the information in this assembly
and maintenance manual.
The documentation must always be available at the operating location of the machine so that
dangers or injuries and damage can be prevented to the greatest extent possible. For storage,
transport, commissioning, operation, maintenance / service or decommissioning, the applicable
national, local and system-specific regulations must be observed.
Special designs and design variants may differ in their technical details! In case of uncertainty,
we strongly recommend consulting Rickmeier GmbH with the data on the nameplate.
Form 229589-7
Prep.: Web/15.03.10
Name / Date
English Page 5 (32)
1.2 Warnings and Symbols

The warnings in this assembly manual must be observed at all times. They are designed for
your personal safety and to prevent property damage. If there are multiple hazards, the warning
for the highest level is used.
Warning Hazard level Consequences of

non-observance
Warns of an immediate Causes death or serious

DANGER danger injury
Warns of a potential danger May cause death or serious

WARNING injury
Warns of a potential May cause minor injury

CAUTION hazardous situation
Warns of a potential May cause property damage

CAUTION hazardous situation
Table 1: Warnings and consequences of non-observance
Symbol Meaning
Hazard symbol
¾ Take action to prevent personal injury and property damage.
¾ Instructions
) 1., 2., ... Instructions consisting of multiple steps
→ Cross reference
Table 2: Symbols and their meaning

Form 229589-7
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Name / Date
English Page 6 (32)
1.3 Basic Safety Rules

The safety instructions, the current national rules and regulations for accident prevention and
also internal working, operational and safety rules of the operator contained in these assembly
instructions must be strictly observed. Failure to observe the safety precautions may lead to
the loss of any and all warranty claims and claims to damages.
If the safety instructions are not observed, the following hazards may be encountered:
• Leakage of hazardous flow media (e.g. explosive, toxic, hot) may endanger persons and
the environment. Leaks must be managed to eliminate any hazards. Legal requirements
must be observed at all times.
• If hot or cold machine parts pose a danger, then these parts must be guarded to prevent
contact by the customer.
• Failure of important functions of the machine or system.
• Reduction of the expected service life of the machine or system.
• Failure of specified maintenance and service methods.
Never remove safety equipment or deactivate it by making modifications to the machine!
Assembly, commissioning, operation, maintenance, de-commissioning must be conducted only
by persons who are qualified as follows:
• They must have carefully read and understood the assembly and maintenance manual(s).
• They must be technically qualified for the planned work and must be authorised by their
employer.
• EC Directive 89/655/EEC Minimum safety and health requirements for the use of
work equipment by workers at work must be observed.
Information attached directly to the gear pump (such as name plate, direction of rotation
arrow, direction of flow arrow, markings of the fluid connections) must always be
observed. These must always be kept in a completely legible condition.
2 Technical data
2.1 Intended use

Rickmeier gear pumps of the R25, R35, R45, R65, R95 model range must be used exclusively
for the supply of lubricating media.
The gear pumps must be used exclusively within the framework of the operational limits agreed
by the contract. The data relevant for operation is set out in the acceptance of order and/or in
the technical documentation.
Use in a potentially explosive environment is only permissible when the gear pump or pump
unit is marked accordingly!
Form 229589-7
Prep.: Web/15.03.10
Name / Date
English Page 7 (32)
2.2 Non-designated use

Non-designated use may result in damage to the gear pump. If the pump is subsequently
operated under conditions other than those specified, this must be cleared with
Rickmeier GmbH, otherwise all warranty claims will be rendered null and void.
Non-designated use Possible consequences
Limits of operation of gear pump or pump unit • Noise generation and damage
not observed to the gear pump by cavitation
→ Acceptance of order or technical • Damage to seals (leakage)
documentation of gear pump or pump • Delivery volume does not conform
unit to order specifications
• Corrosion in the gear pump
• Entry pressure too low or too high • Damage to bearings, possible failure
• Outlet pressure too low or too high of gear pump
• Operating temperature too low or too • Damage to rotor housing (leakage)
high • Motor damage
• Viscosity of flow medium too low or too
high
• Speed too low or too high
• Chemically aggressive constituents in
the flow medium
Limit value for flow medium with solid • Damage to bearings

particles exceeded • Possible failure of gear pump as a result
→ Acceptance of order or technical of axial and radial corrosion in the gear
documentation of gear pump or pump pump
unit • Delivery volume does not conform
to order specifications
→ Assembly and maintenance manual,
Chapter 2.3 “Flow medium“
Limit value for gas constituents (undissolved • Noise generation by cavitation

gas) in flow medium exceeded • Delivery volume does not conform
→ Acceptance of order or technical to order specifications
documentation of gear pump or pump
unit
→ Assembly and maintenance manual,
Chapter 2.3 “Flow medium“
Form 229589-7
Prep.: Web/15.03.10
Name / Date
English Page 8 (32)
Non-designated use Possible consequences
Parallel operation of two gear pumps without • Delivery volume does not conform
protection by check valves to order specifications
• Damage to bearings
• Possible failure of gear pump as a result
of axial and radial corrosion in the gear
pump
Incorrect direction of rotation • Damage to seals (leakage)

• No pumping
• Possible failure of gear pump as a result
of axial and radial corrosion in the gear
pump
Table 3: Consequences of non-designated use
2.3 Flow medium

The flow medium must have lubricating properties to ensure a long service life and maximum
operating safety. The flow medium should always be free of hard solid particles.
Consideration must be given also to the following:
Property Unit min. max.
Kinematic viscosity mm2/s 5 15000
Degree of contamination ISO 4406:1999 - 21/19/17
Gas content (undissolved) Vol.-% - 10
Table 4: Flow medium

Undissolved gas in the flow medium leads to increased noise emissions.
Form 229589-7
Prep.: Web/15.03.10
Name / Date
English Page 9 (32)
2.4 Sound pressure level

The sound pressure level reference values measured on the test stand by Rickmeier GmbH are
applicable for gear pumps only. With pump units the increase in the sound pressure level is
minimal and is covered by the tolerance specified in Table 5.
Measurement conditions:
• Operating conditions: viscosity 33 mm2/s, outlet pressure 25 bar, cavitation-free
• Distance to gear pump: 1 m
• Motor: IEC standard motor, n = 1450 min-1
Gear pump R25 R35 R45 R65 R95
Max. sound pressure level LpA ± 3 dB(A) 67 73 78 85 93
Table 5: Sound pressure level
3 Description
Figure 1: Gear pump delivery principle

Rickmeier gear pumps of the R25, R35, R45, R65, R95 model range are rotary displacement
pumps. When the gear wheels turn, the flow medium enclosed in the space between the teeth
is transported from the suction to the pressure side. Then the flow medium is displaced toward
the pressure side by the intermeshing teeth. The transport of the flow medium results in a
pressure drop on the suction side of the gear pump. The flow medium compensates for this
pressure drop by flowing in, thereby maintaining the feed process.
This process is the same for both gaseous and liquid flow media. As a result, the gear pump is
capable of priming the suction pipe itself until it is completely filled with liquid flow medium.
Form 229589-7
Prep.: Web/15.03.10
Name / Date
English Page 10 (32)
3.1 Pressure relief valve

The pressure relief valve integrated in the end cover of the gear pump as an option is designed
as a spring-loaded valve. It may only be used as an occasionally, briefly actuated valve for
pressure relief. If a larger partial volume of the flow medium must be drained off over
an extended period, a separate valve with a return pipe to the suction tank in the pipe
(e.g. Rickmeier valves RSn, DBV40, DBV80, DB9) or another form of pressure relief must be
provided. This also applies if the pressure pipe may become completely blocked during gear
pump operation.
Special designs and design variants may differ in their technical details!
3.2 Using pressure relief valve R25, R35 DB (if installed)
V1 End cover with

integrated pressure
relief valve
V2 Piston
V3 Compression spring
V4 Spindle
V5 Cap nut
Figure 2: Pressure relief valve R25 DB V6 Hexagonal nut
V7 Copper sealing ring
Figure 3: Pressure relief valve R35 DB

Form 229589-7
Prep.: Web/15.03.10
Name / Date
CAUTION
Risk of injury due to leaks of dangerous flow media
(e.g. explosive, toxic, hot)
¾ During the pressure adjustment the spindle (Item V4) may only be screwed in clockwise
(pressure increase).
The spindle is not secured to prevent unscrewing!
) In the case of later pressure adjustment, the following must be observed:

1. Unscrew cap nut (Item V5).
2. Unscrew hexagonal nut (Item V6).
3. Adjust pressure by adjustment of the spindle (Item V4).
Pressure increase = direction of rotation clockwise
4. Replace copper sealing ring (Item V7) (DIN 7603-A21x26-Cu).
5. Tighten sealing hexagon nut (Item V6).
6. Tighten cap nut (Item V5).
Figure Item Tightening torque [Nm]
Pressure relief valve R25 DB 2 V5 70
V6 70
Pressure relief valve R35 DB 3 V5 100
V6 100
Table 6: Tightening torques for pressure relief valves

Form 229589-7
Prep.: Web/15.03.10
Name / Date
4 Transport and storage

Dispose of the packing material after unpacking according to the applicable legal regulations.
Connections of the gear pump must be closed during transport and storage. The closures
should not be removed until just before installation to prevent ingress of impurities into the gear
pump.
The gear pump or the pump unit must be kept stable during transport. The gear pump or the
pump unit must not be tilted more than 10° in any direction (e.g. use braces, not included with
the equipment supplied by Rickmeier GmbH).
4.1 Storage and preservation

The gear pump is coated inside with test oil left from the test run and is therefore preserved.
Renewed preservation is only permitted in consultation with Rickmeier GmbH.
Always protect the gear pump against damage due to moisture, dust, water and/or other
contaminants. Store the gear pump in a clean and dry place (relative humidity ≤ 70%) at
temperatures between -25 °C and 40 °C; uncoated components should be stored at a relative
humidity ≤ 40%. Gear pumps with a rotary shaft seal or mechanical seal should be
commissioned no later than 24 months after delivery. Storage conditions which differ from this
are subject to separate consultation.
The coating supplied by Rickmeier GmbH is a base coat designed for protection from corrosion
only during transport and storage. Do not damage the coating.
Form 229589-7
Prep.: Web/15.03.10
Name / Date
4.2 Lifting the gear pump or pump unit
Figure 4: Transport / Lifting
WARNING
Danger of death or serious injury
if the gear pump or pump unit falls
¾ Use a suitable hoist.

→ For weight specifications see acceptance of order or technical documentation
for the gear pump or the pump unit
¾ Do not remain under suspended loads.
If the gear pump or the pump unit is lifted with straps, the centre of gravity must be between
the straps to prevent the gear pump or the pump unit from tipping (see Figure 4).
Form 229589-7
Prep.: Web/15.03.10
Name / Date
5 Set-up / Mounting and Connection
5.1 Set-up / Mounting
5.1.1 Preparation
CAUTION
Damage to gear pump or pump unit by inadequate fastening
¾ Install the equipment on an even surface securely fastened foot and flange fastening
and accurate alignment.
) Preparing for set-up:

1. Checking the environmental conditions.
→ Acceptance of order or technical documentation of gear pump or pump unit
2. Ensure that there is sufficient space for set-up, mounting, operation and
maintenance.
3. Ensure that the foundation is flat, clean and has sufficient load capacity.
4. Place the gear pump or the pump unit in the specified position.
5. Fasten gear pump or pump unit.
The drive of the gear pump must be adjusted to its power input.
Appropriate contact protection must be installed for pump models without factory-installed
clutch guards.
→ E.g. Machinery Directive 2006/42/EC Section 1.3.8
Drive elements (drive pinion) must be fitted with ISO fit H7 on the drive shaft of the gear pump,
unless otherwise specified. Drive elements (driving pinion) must not be driven on with hammer
blows, as the gear pump can be damaged in the process.
Form 229589-7
Prep.: Web/15.03.10
Name / Date
5.1.2 Clutch alignment
CAUTION
Damage to gear pump by faulty alignment of clutch
¾ When aligning the driving gear shaft of the gear pump to the drive, the permissible
differences of the clutch may not be exceeded.
→ Clutch operating manual
Drive elements (clutches) must be fitted with ISO fit H7 on the drive shaft of the gear pump,
unless otherwise specified. Drive elements (clutches) must not be driven on with hammer
blows, as the gear pump can be damaged in the process.
5.1.3 Motor mounting
) Motor mounting:
1. Insert the motor key.
2. Slide on motor side clutch halves and tighten the setscrew.
→ Clutch operating manual
3. Fastening the motor to the bracket.
Use the specified threaded holes only to attach the motor. The screws must be
locked in position with Loctite medium 242 or 243 or comparable adhesives.
→ For screw tightening torques see Table 7
Thread
Tightening torque [Nm]
(Min. strength class 8.8)
M8 M10 M12 M16 M20 M24
Bracket of aluminium 12 23 40 100 190 -
Bracket of steel and grey cast

27 53 92 230 460 590
iron
Table 7: Tightening torques for brackets

Form 229589-7
Prep.: Web/15.03.10
Name / Date
5.2 Planning and connection of pipes
5.2.1 Suction pipe design, NPSHR value

For correct operation the static pressure immediately at the inlet to the gear pump must not be
less than -0.4 bar under any operating conditions (corresponding to 0.6 bar absolute).
Deviations from this specification must be agreed with Rickmeier GmbH when ordering.
→ Acceptance of order or technical documentation of gear pump or pump unit
It is therefore advisable to calculate or measure the lowest possible static pressure at the pump
entrance during operation. When doing so, all hydraulic resistance in the planned suction pipe
must be taken into account. This is particularly important if a filter that may become partially
blocked over time is to be installed in the suction line. In this case, we recommend monitoring
the pump inlet pressure with a pressure measuring device as close to the gear pump as
possible and that the filter is serviced regularly.
If no measuring connection is available in the suction pipe, the pressure gauge connection
facing the suction side can also be used for this purpose for gear pumps with a pressure relief
valve. Otherwise, the suction pipe must be absolutely leak-tight so that no air can be aspirated.
The NPSHR value of the pumps frequently used for comparison with the NPSHA value of
a system is provided in Figure 5.
Figure 5: NPSHR
(ρ: density of the flow medium)
Form 229589-7
Prep.: Web/15.03.10
Name / Date
5.2.2 Connection of pipes
CAUTION
Damage by impurities in the pipes
¾ The interior of the gear pump and the pipeline must be free of foreign particles.
Residues are certain to lead to failures (pressure drop).
¾ Impurities resulting from welding (e.g. welding beads, grinding dust) must not penetrate
the gear pump and the pipes. Connections must be closed during welding.
CAUTION
Damage by distortion during mounting
¾ The pipes must be free from tension.

¾ Do not exceed approved forces and torques at pipe connections.
Remove any cover screws, flange covers, shipping covers where present.
The gear pump connections and the mating surfaces must not be damaged. They must be free
from paint residues and impurities. Maintain cleanliness as much as possible.
The connections must be sealed in accordance with the operating conditions (flow medium,
pressure, temperature). All connections must match accurately. Centre the seals between
the flanges. Use only male components with precisely fitted cylindrical threads for connections
for models with internal thread.
Form 229589-7
Prep.: Web/15.03.10
Name / Date
5.3 Electrical connection
DANGER
Danger of death by electrocution
¾ The pump unit must be connected by an authorised electrical technician only.

¾ Disconnect the electrical power supply.
→ Motor operating manual
) Connecting motor:
1. Open terminal box on motor.
2. Ensure that the connector cable is not live.
3. Connect motor as shown in the wiring diagram.
4. Close terminal box on motor.
5. Install Emergency Stop switch.
6 Commissioning
6.1 Before commissioning
CAUTION
Danger of injury by leakage of drops of flow medium
¾ Catch leaking flow medium safely (e.g. collection trough under the gear pump) and
dispose of in accordance with environmental regulations.
CAUTION
Damage from overheating of the gear pump
¾ The gear pump must not pump against the closed pressure line.
Form 229589-7
Prep.: Web/15.03.10
Name / Date
) Before commissioning:
1. Fill gear pump with flow medium.
2. Fill suction and feed line with flow medium.
When operating two gear pumps in parallel which are protected against each other with
non-return valves, both gear pumps must be bled on the pressure side. The same applies to a
gear pump working against a closed system (loaded non-return valve etc.).
With difficult suction conditions, the gear pump must be installed so that the driving gear shaft
and the gear shaft are located above each other. This installation position provides better
priming after extended downtime due to the residual oil remaining in the gear pump.
The gear pump is prevented from running empty if:
• A check valve is installed in the suction line.
• The suction and pressure line at the gear pump are designed to form a siphon.
6.2 Dry running
CAUTION
Damage from running the gear pump dry
¾ The gear pump must be filled with flow medium before starting it for the first time.
Dry running frequently occurs during start-up with unfilled suction pipe or during operation when
the supply of flow medium has been interrupted.
Gear pumps wetted with flow medium inside beforehand can be operated for up to 20 minutes
under the following conditions:
• The gear pump is driven via a clutch, i.e. without radial force.
• The pressures at the inlet and outlet of the gear pump are virtually identical.
On gear pumps driven via a pinion, chain or belt, dry running is not permissible and must be
avoided by the operator (fill gear pump with flow medium prior to start-up).
Form 229589-7
Prep.: Web/15.03.10
Name / Date
6.3 Direction of rotation
6.3.1 Checking the direction of rotation
Figure 6: Direction of rotation

(direction of rotation R: clockwise)
(direction of rotation L: anticlockwise)
The direction of rotation is marked by the rotation arrow (Item P1) on the gear pump.
When checking the direction of drive rotation, a pressure build-up in the suction pipe must be
prevented (e.g. caused by an integrated non-return valve). Otherwise the shaft seal may be
damaged if the direction of rotation is incorrect.
DANGER
Danger of death by rotating parts
¾ Lock or remove the key when checking the direction of rotation to prevent it from flying
out.
CAUTION
Damage by incorrect direction of rotation
¾ Disconnect the motor from the gear pump.

Form 229589-7
Prep.: Web/15.03.10
Name / Date
) Checking the direction of rotation:

1. Disconnect the clutch so the gear pump cannot be driven.
If this is not possible, the pipes must be disconnected to prevent damage to the gear
pump.
2. Switch motor on and then off immediately.
3. Check that the fan impeller of the motor rotates in the direction of the rotation arrow
on the gear pump (see Figure 6).
4. If the direction of rotation is incorrect, reverse the phases.
5. Connect the motor again.
6.3.2 Reversing the direction of rotation

Rickmeier gear pumps of the R25, R35, R45, R65, R95 model range are designed so the
direction of rotation can be changed at any time. This also reverses the direction of flow.
Rickmeier GmbH must be consulted before conversion to a different direction of rotation and
therefore reversing the flow direction.
The direction of rotation of gear pumps with a mechanical seal cannot be changed after
delivery. Rickmeier GmbH must carry out the conversion to a different direction of rotation and
therefore reversing the flow direction.
Form 229589-7
Prep.: Web/15.03.10
Name / Date
6.4 Commissioning
Commissioning can be conducted as follows:
• The gear pump or the pump unit is correctly mounted, secured and connected.
• The motor is correctly mounted and connected to the electrical power supply.
• All connections are attached to the pipes without tension.
• The pipes are free from impurities.
• All safety equipment is installed and the operation has been tested.
• The gear pump has been filled and bled.
CAUTION
CAUTION
) Commissioning:
1. Open suction and pressure side fittings completely.
2. Switch on motor.
3. Run gear pump for some minutes to bleed the pipes completely.
4. As soon as the operating point is reached, check that the gear pump does not leak.
5. If leaks are detected, switch off the motor and check connections for leaks.
Form 229589-7
Prep.: Web/15.03.10
Name / Date
6.5 Recommissioning
CAUTION
CAUTION
→ Chapter 6.1 "Before commissioning"
7 Dismantling
WARNING
Danger of injury by hot components
¾ Allow flow medium to cool to ambient temperature.
CAUTION
Danger of injury
by leakage of hot, toxic or corrosive flow medium
¾ Observe safety regulations when working with hazardous flow media.

¾ Assembly work must be carried out by qualified personnel only.
Form 229589-7
Prep.: Web/15.03.10
Name / Date
) Dismantling:
1. Before disassembly the gear pump drive must be disconnected from the electrical
power supply by an authorised electrical technician.
2. In case of operation at high temperatures the flow medium must be left to cool to
ambient temperature before disassembly.
3. Block suction and pressure line.
4. Unscrew the fastening screws of the suction and pressure connections and collect
the flow medium with a collection trough.
Attention: Loosen the pressure side first.
5. Once the flow medium has drained completely, remove the suction and pressure
connection flange.
6. Close the connections of the gear pump and the relevant mating surfaces with an oil-
tight seal.
8 Maintenance / Service
8.1 Gear pump

Rickmeier gear pumps of the R25, R35, R45, R65, R95 model range usually require little
maintenance when operated within the permissible operating limits. If a gear pump becomes
unusable as the result of wear, it must be replaced. The installation of replacement parts
generally does not restore the original performance.
The service life of the shaft seals is mainly dependent on the manner of operation of the gear
pump and the purity and quality of the flow medium. As a result, in many cases no reliable
prediction as to the time of failure can be made. For gear pumps with shaft seals it is
recommended that they are inspected externally for signs of leakage at regular intervals
(recommendation: after 48 h, then every 4000 operating hours). If a high danger potential
exists due to the flow medium, a check should be made at shorter intervals.
When operated in a potentially explosive environment, the maintenance intervals of the related
ATEX operating instructions BA2-0NNN-113 apply.
Form 229589-7
Prep.: Web/15.03.10
Name / Date
8.2 Pump unit

The maintenance of pump units also requires compliance with the maintenance intervals and
service work of the clutch and the motor (see Table 8).
Product Clutch model Maintenance information
Unit without drive Rotex and Bowex clutch Gear pump:

→ Chapter 8.1 “Gear pump“
Clutch: maintenance-free
Other clutches Gear pump:

Clutch:
→ Separate operating manual
Unit with drive Rotex and Bowex clutch Gear pump:

Clutch: maintenance-free
Motor:
Other clutches Gear pump:

Clutch:
Motor:
Table 8: Maintenance of pump units

Form 229589-7
Prep.: Web/15.03.10
Name / Date
9 Conversion / Changes
Conversion or changes are permitted only after prior consultation with Rickmeier GmbH.
Original spare parts and accessories approved by Rickmeier GmbH maintain safety. The use of
other parts may mean that the manufacturer is no longer liable for any consequences. When
ordering spare parts, please always give the data on the rating plate.
10 Decommissioning
CAUTION
Environmental damage from leaking flow medium
¾ Observe safety regulations when working with hazardous flow media.

¾ Observe local regulations for disposal.
When decommissioning the gear pump, ensure that no pressure greater than atmospheric
pressure exists in the gear pump, and that the drive cannot be started accidentally.
For environmental protection reasons, disposal is permitted by licensed specialised companies
only.
11 Malfunctions / Causes / Remedies

The following table contains directions for remedying any faults and finding their possible
causes. If faults that are not listed here occur, we recommend contacting Rickmeier GmbH.
If it is necessary to remove the gear pump for troubleshooting, observe the recommendations in
Chapter 7 "Dismantling" and 10 "Decommissioning".
Form 229589-7
Prep.: Web/15.03.10
Name / Date
Fault Possible causes Remedy
Gear pump has Gear pump direction Compare direction of rotation with the mark
no suction of rotation is incorrect on the gear pump. Reverse motor poles
if necessary.
→ Chapter 6.3 “Direction of rotation“
Gear pump not Fill gear pump with flow medium.

sufficiently filled with flow
medium (dry running)
Suction line or seals leak Inspect suction line for leaks.
Check gear pump seals, replace if

necessary.
If there is a pressure relief valve installed:

check seals, replace if necessary.
Pressure drop in suction Enlarge pipe cross-section.

line too high
Shorten suction line.
Increase suction side fluid level.
If filter is installed: clean it, if necessary

install filter with larger mesh size.
Attention: Note approved mesh size
(max. 60 µm).
Pressure relief valve Remove pressure relief valve, clean, replace

dirty or damaged defect parts.
Air inclusions or gas Check pipe for leaks. Bleed pressure line.
bubbles in the flow
medium Terminate return lines below the oil level
of the tank.
Form 229589-7
Prep.: Web/15.03.10
Name / Date
Gear pump does not vent Check pipe for leaks. Bleed pressure line.
Terminate return lines below the oil level

of the tank.
Delivery volume Suction line or seals leak Inspect suction line for leaks.
too low or outlet
pressure too low Check gear pump seals, replace
if necessary.


line too high
If filter installed: clean it, if necessary

install filter with larger mesh size.
(max. 60 µm).
Opening pressure of Set opening pressure approx. 10% above

pressure relief valve the value of the operating pressure.
not correct
→ Acceptance of order or technical
documentation of gear pump
Pressure relief valve Remove pressure relief valve, clean,

dirty or damaged replace defect parts.
Motor operated with Check circuit type, speed and power

incorrect voltage or consumption of drive motor. Compare
frequency voltage and frequency with motor type plate.
Form 229589-7
Prep.: Web/15.03.10
Name / Date
Flow media with high In the case of flow media with high vapour
vapour pressure pressure (petrol, solvents, paints etc.)
the flow medium must flow around the gear
pump. Motor speed max. 1000 min-1.
bubbles in the flow
of the tank.
Viscosity of flow medium Increase temperature of flow medium.

too high
Reduce speed.
Viscosity of flow medium Reduce temperature of flow medium.

too low
Increase speed.
Size of gear pump Install larger gear pump.

too small
Outlet pressure Pressure relief valve Remove pressure relief valve, clean,
too high dirty or damaged replace defective parts.
Maximum approved Reduce speed.

speed exceeded

too high
Reduce speed.
Gear pump Suction line or seals leak Inspect suction line for leaks.
is noisy
Check gear pump seals, replace
if necessary.

Form 229589-7
Prep.: Web/15.03.10
Name / Date

line too high
If filter installed: clean it, if necessary install

filter with larger mesh size.
(max. 60 µm).
Opening pressure Set opening pressure approx. 10% above

of pressure relief valve the value of the operating pressure.
not correct
Gear pump has With unpressurised pumping of liquid flow

no pressure media load the gear pump with 1-2 bar.
Maximum approved Reduce speed.

speed exceeded
Flow media with high In the case of flow media with high vapour
vapour pressure pressure (petrol, solvents, paints etc.)
the flow medium must flow around the gear
pump. Motor speed max. 1000 min-1.
bubbles in the flow
of the tank.

too high
Reduce speed.
Form 229589-7
Prep.: Web/15.03.10
Name / Date
Gear pump does Gear pump not Fill gear pump with flow medium.
not start, stops sufficiently filled with flow
suddenly or has medium (dry running)
stalled
Foreign bodies in Remove and clean gear pump, replace
the gear pump defective parts, smooth surface damage.
Power of motor too low Install larger motor.


too high
Reduce speed.
Viscosity of flow medium Reduce temperature of flow medium.

too low
Increase speed.
Bearings overloaded Check the value of the differential pressure

by excessive differential
pressure
Bearings overloaded by Reduce temperature of flow medium.

excessively low viscosity
Increase speed.
Use higher viscosity flow medium.
Gear pump distorted Remove gear pump, check pipes.

Form 229589-7
Prep.: Web/15.03.10
Name / Date
Pressure relief Opening pressure of Set opening pressure approx. 10% above
valve is noisy pressure relief valve the value of the operating pressure.
not correct
bubbles in the flow
of the tank, check oil system.
Check seals, screw fastenings.
Table 9: Troubleshooting
AN-ZU Changes Date Editor

05 ÄM 10/021 15.03.2010 Web
Form 229589-7
Low voltage motors
Manual
Installation, operation, maintenance and safety manual .......................................................................................... EN 3
Montage-, Betriebs-, Wartungs- und Sicherheitsanleitung . ................................................................................... DE 21
Manuel d’installation, d’exploitation, de maintenance et de sécurité ...................................................................... FR 39
Manual de instalación, funcionamiento, mantenimiento y seguridad ...................................................................... ES 59
Manuale d’installazione, funzionamento e manutenzione . ....................................................................................... IT 79
Manual de instalação, operação, manutenção e segurança ....................................................................................PT 99
Installations-, driffts-, underhålls- och säkerhetsmanual ...................................................................................... SV 119
Asennus-, käyttö-, kunnossapito- ja turvallisuusohje . ........................................................................................... FI 137
More languages – see web site www.abb.com/motors&generators > Motors > Document library
EC Declaration of Conformity
The Manufacturer: (Name and address of the manufacturer)
hereby declares that
The Products: (Product identification)
are in conformity with the corresponding essential requirements of following EC directive:
Directive 2006/95/EC (of 12 December 2006).
The motors are in compliance with the following harmonized standard:
EN 60 034-1(2004)
which thus comply with Principal Elements of the Safety Objectives for Electrical Equipement stated in
Annex I of said directive.
Note: When installing motors for converter supply applications, additional requirements must be
respected regarding the motor as well as the installation, as described in installation manual delivered
with converters.
Year of CE marking :
Signed by
--------------------------
Title --------------------------
Date --------------------------
2 ABB Motors and Generators | Low voltage motor manual 01-2009

Low Voltage Motors
Installation, operation, maintenance and safety manual
List of Contents Page

1. Introduction .............................................................................................................................................. 5
1.1 Declaration of Conformity . ................................................................................................................. 5
1.2 Validity ............................................................................................................................................... 5
2. Handling . .................................................................................................................................................. 6
2.1 Reception check ................................................................................................................................ 6
2.2 Transportation and storage ................................................................................................................ 6
2.3 Lifting . ............................................................................................................................................... 6
2.4 Machine weight . ................................................................................................................................ 6
3. Installation and commissioning . ............................................................................................................ 7

3.1 General .............................................................................................................................................. 7
3.2 Insulation resistance check ................................................................................................................ 7
3.3 Foundation . ....................................................................................................................................... 7
3.4 Balancing and fitting coupling halves and pulleys ............................................................................... 8
3.5 Mounting and alignment of the motor . ............................................................................................... 8
3.6 Slide rails and belt drives . .................................................................................................................. 8
3.7 Machines with drain plugs for condensation . ..................................................................................... 8
3.8 Cabling and electrical connections ..................................................................................................... 8
3.8.1 Connections for different starting methods .............................................................................. 9
3.8.2 Connections of auxiliaries . ...................................................................................................... 9
3.9 Terminals and direction of rotation ...................................................................................................... 9
4. Operation ................................................................................................................................................ 10
4.1 Use .................................................................................................................................................. 10
4.2 Cooling ............................................................................................................................................ 10
4.3 Safety considerations . ..................................................................................................................... 10
Low voltage motor manual 01-2009 | ABB Motors and Generators EN-3
5. Low voltage motors in variable speed operation ............................................................................... 11
5.1 Introduction . .................................................................................................................................... 11
5.2 Winding insulation ............................................................................................................................ 11
5.2.1 Phase to phase voltages ....................................................................................................... 11
5.2.1 Phase to ground voltages ..................................................................................................... 11
5.2.3 Selection of winding insulation for ACS550- and ACS800-converters ................................... 11
5.2.4 Selection of winding insulation with all other converters . ....................................................... 11
5.3 Thermal protection of windings ........................................................................................................ 11
5.4 Bearing currents .............................................................................................................................. 12
5.4.1 Elimination of bearing currents with ABB ACS550 and ACS800 converters . ......................... 12
5.4.2 Elimination of bearing currents with all other converters . ....................................................... 12
5.5 Cabling, grounding and EMC ........................................................................................................... 12
5.6 Operating speed .............................................................................................................................. 12
5.7 Dimensioning the motor for variable speed application ..................................................................... 12
5.7.1 General ................................................................................................................................. 12
5.7.2 Dimensioning with ABB ACS800 converters with DTC control .............................................. 12
5.7.3 Dimensioning with ABB ACS550 converters ......................................................................... 13
5.7.4 Dimensioning with other voltage source PWM-type converters ............................................. 13
5.7.5 Short time overloads ............................................................................................................. 13
5.8 Rating plates . .................................................................................................................................. 13
5.9 Commissioning the variable speed application ................................................................................. 13
6. Maintenance . ......................................................................................................................................... 14
6.1 General inspection ........................................................................................................................... 14
6.1.1 Standby motors .......................................................................................................................14
6.2 Lubrication ................................................................................................................................................ 14
6.2.1 Machines with permanently greased bearings ....................................................................... 14
6.2.2 Motors with regreasable bearings ......................................................................................... 15
6.2.3 Lubrication intervals and amounts ......................................................................................... 15
6.2.4 Lubricants . ........................................................................................................................... 17
7. After Sales Support ............................................................................................................................... 18

7.1 Spare parts ...................................................................................................................................... 18
7.2 Rewinding . ...................................................................................................................................... 18
7.3 Bearings .......................................................................................................................................... 18
8. Environmental requirements . ............................................................................................................... 18

8.1 Noise levels . .................................................................................................................................... 18
9. Troubleshooting ..................................................................................................................................... 19
EN-4 ABB Motors and Generators | Low voltage motor manual 01-2009
1. Introduction
NOTE!
1.2 Validity
The instructions are valid for the following ABB electrical
These instructions must be followed to ensure safe
machine types, in both motor and generator operation.
and proper installation, operation and maintenance
of the machine. They should be brought to the series MT*, MXMA,
attention of anyone who installs, operates or series M2A*/M3A*, M2B*/M3B*, M4B*, M2C*/M3C*,
maintains the machine or associated equipment. M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*,
The machine is intended for installation and use by M2R*/M3R*, M2V*/M3V*
qualified personnel, familiar with health and safety in frame sizes 56 - 450.
requirements and national legislation. Ignoring these
instructions may invalidate all applicable warranties. There is a separate manual for e.g. Ex motors ‘Low voltage
motors for hazardous areas: Installation, operation and
maintenance Manual’ (Low Voltage Motors/Manual for Ex-
motors).
1.1 Declaration of Conformity Additional information is required for some machine types
Declarations of Conformity with respect to the Low voltage due to special application and/or design considerations.
Directive 73/23/EEC amended by Directive 93/68 EEC are
Additional information is available for the following motors:
issued separately with individual machines.
– roller table motors
The Declaration of Conformity also satisfies the – water cooled motors
requirements of a Declaration of Incorporation with – open drip proof motors
respect to the Machinery Directive 98/37/EEC, – smoke venting motors
Art 4.2 Annex II, sub B – brake motors
– motors for high ambient temperatures
2. Handling Motors with the same frame may have a different center of
gravity because of different output, mounting arrangements
and auxiliary equipment.
2.1 Reception check
Damaged lifting lugs must not be used. Check that
Immediately upon receipt check the motor for external eyebolts or integrated lifting lugs are undamaged before
damage (e.g. shaft-ends and flanges and painted surfaces) lifting.
and if found, inform the forwarding agent without delay.
Lifting eyebolts must be tightened before lifting. If needed,
Check all rating plate data, especially voltage and winding the position of the eyebolt can be adjusted using suitable
connection (star or delta). The type of bearing is specified washers as spacers.
on the rating plate of all motors except the smallest frame
sizes. Ensure that proper lifting equipment is used and that the
sizes of the hooks are suitable for the lifting lugs.
2.2 Transportation and storage Care must be taken not to damage auxiliary equipment and
cables connected to the motor.
The motor should always be stored indoors (above
–20°C), in dry, vibration free and dust free conditions.
During transportation, shocks, falls and humidity should be 2.4 Machine weight
avoided. In other conditions, please contact ABB. The total machine weight can vary within the same
Unprotected machined surfaces (shaft-ends and flanges) frame size (center height) depending on different output,
should be treated against corrosion. mounting arrangement and auxiliaries.
It is recommended that shafts are rotated periodically by The following table shows estimated maximum weights
hand to prevent grease migration. for machines in their basic versions as a function of frame
material.
Anti-condensation heaters, if fitted, are recommended to
be used to avoid water condensing in the motor. The actual weight of all ABB’s motors, except the smallest
frame sizes (56 and 63) is shown on the rating plate.
The motor must not be subject to any external vibrations at
standstill so as to avoid causing damage to the bearings. Frame Aluminum Cast iron Steel
size Add.
Motors fitted with cylindrical-roller and/or angular contact Weight Weight Weight for brake
kg kg kg
bearings must be fitted with locking devices during
56 4.5 - -
transport.
63 6 - -
71 8 13 5
2.3 Lifting 80 12 20 8
90 17 30 10
All ABB motors above 25 kg are equipped with lifting lugs 100 25 40 16
or eyebolts. 112 36 50 20
132 63 90 30
Only the main lifting lugs or eyebolts of the motor should be 160 95 130 30
used for lifting the motor. They must not be used to lift the 180 135 190 45
motor when it is attached to other equipment. 200 200 275 55
225 265 360 75
Lifting lugs for auxiliaries (e.g. brakes, separate cooling 250 305 405 75
fans) or terminal boxes must not be used for lifting the 280 390 800 600 -
motor. 315 - 1700 1000 -
355 - 2700 2200 -
400 - 3500 3000 -
450 - 4500 - -
3. Installation and commissioning
Insulation resistance, corrected to 25°C, must exceed the
WARNING reference value, i.e. 100 MΩ (measured with 500 or 1000 V
Disconnect and lock out before working on the DC). The insulation resistance value is halved for each 20°C
motor or the driven equipment. rise in ambient temperature.
WARNING
3.1 General The motor frame must be grounded and the
All rating plate values must be carefully checked to ensure windings should be discharged against the frame
that the motor protection and connection will be properly immediately after each measurement to avoid risk of
done. electrical shock.
WARNING If the reference resistance value is not attained, the

In case of motors mounted with the shaft upwards winding is too damp and must be oven dried. The oven
and water or liquids are expected to go down along temperature should be 90°C for 12-16 hours followed by
the shaft, the user must take in account to mount 105°C for 6-8 hours.
some means capable of preventing it.
Drain hole plugs, if fitted, must be removed and closing
valves, if fitted, must be opened during heating. After
heating, make sure the plugs are refitted. Even if the drain
Remove transport locking if employed. Turn shaft by hand plugs are fitted, it is recommended to disassemble the end
to check free rotation if possible. shields and terminal box covers for the drying process.
Windings drenched in seawater normally need to be

Motors equipped with roller bearings:
rewound.
Running the motor with no radial force applied to the shaft
may damage the roller bearing.
3.3 Foundation
Motors equipped with angular contact bearing: The end user has full responsibility for preparation of the
Running the motor with no axial force applied in the right foundation.
direction in relation to the shaft may damage the angular
contact bearing. Metal foundations should be painted to avoid corrosion.
Foundations must be even, see figure below, and

WARNING sufficiently rigid to withstand possible short circuit forces.
For machines with angular contact bearings the axial They must be designed and dimensioned to avoid the
force must not by any means change direction. transfer of vibration to the motor and vibration caused by
resonance.
The type of bearing is specified on the rating plate. Ruler
Motors equipped with regreasing nipples:

When starting the motor for the first time, or after long Note! Height difference shall
storage, apply the specified quantity of grease. not exceed ± 0,1mm referred
to any other motor foot
For details, see section “6.2.2 Motors with regreasable
bearings”.
3.2 Insulation resistance check

Measure insulation resistance before commissioning and Foot location
when winding dampness is suspected.
WARNING
Disconnect and lock out before working on the
motor or the driven equipment.
3.4 Balancing and fitting coupling 3.6 Slide rails and belt drives
halves and pulleys Fasten the motor to the slide rails as shown in Figure 2.
As standard, balancing of the motor has been carried out Place the slide rails horizontally on the same level.
using half key
Check that the motor shaft is parallel with the drive shaft.
When balancing with full key, the shaft is marked with
YELLOW tape, with the text “Balanced with full key”.
In case of balancing without key, the shaft is marked with Belts must be tensioned according to the instructions of
BLUE tape, with the text “Balanced without key”. the supplier of the driven equipment. However, do not
exceed the maximum belt forces (i.e. radial bearing loading)
Coupling halves or pulleys must be balanced after stated in the relevant product catalogues.
machining the keyways. Balancing must be done in
accordance with the balancing method specified for the
motor. WARNING
Excessive belt tension will damage bearings and can
Coupling halves and pulleys must be fitted on the shaft by cause shaft damage.
using suitable equipment and tools which do not damage
the bearings and seals.
Never fit a coupling half or pulley by hammering or by

removing it using a lever pressed against the body of the 3.7 Machines with drain plugs
motor.
for condensation
Check that drain holes and plugs face downwards.
3.5 Mounting and alignment
Machines with sealable plastic drain plugs are delivered in
of the motor open position. In very dusty environments, all drain holes
Ensure that there is enough space for free airflow around should be closed.
the motor. Minimum requirements for free space behind the
motor fan cover can be found from the product catalog or
from the dimension drawings available from the web: see 3.8 Cabling and electrical
www.abb.com/motors&generators. connections
Correct alignment is essential to avoid bearing, vibration The terminal box on standard single speed motors normally
and possible shaft failures. contains six winding terminals and at least one earth
terminal.
Mount the motor on the foundation using the appropriate
bolts or studs and place shim plates between the In addition to the main winding and earthing terminals, the
foundation and the feet. terminal box can also contain connections for thermistors,
heating elements or other auxiliary devices.
Align the motor using appropriate methods.
Suitable cable lugs must be used for the connection of all
If applicable, drill locating holes and fix the locating pins into
main cables. Cables for auxiliaries can be connected into
position.
their terminal blocks as such.
Mounting accuracy of coupling half: check that clearance
Machines are intended for fixed installation only. If not
b is less than 0.05 mm and that the difference a1 to a2 is
otherwise specified, cable entry threads are metric. The IP-
also less than 0.05 mm. See Figure 3.
class of the cable gland must be at least the same as those
Re-check the alignment after final tightening of the bolts or of the terminal boxes.
studs.
Unused cable entries must be closed with blanking
Do not exceed permissible loading values for bearings as elements according to the IP class of the terminal box.
stated in the product catalogues.
The degree of protection and diameter are specified in the
documents relating to the cable gland.
3.8.2 Connections of auxiliaries
WARNING If a motor is equipped with thermistors or other RTDs
Use appropriate cable glands and seals in the cable (Pt100, thermal relays, etc.) and auxiliary devices, it is
entries according to the type and diameter of the recommended they be used and connected by appropriate
cable. means. Connection diagrams for auxiliary elements and
connection parts can be found inside the terminal box.
Additional information on cables and glands suitable for Maximum measuring voltage for the thermistors is 2.5 V.
variable speed applications can be found from chapter 5.5. Maximum measuring current for Pt100 is 5 mA. Using a
higher measuring voltage or current may cause errors in
Earthing must be carried out according to local regulations readings or damage the system.
before the machine is connected to the supply voltage.
The insulations of the winding thermal sensors is of basic
Ensure that the motor protection corresponds to the type. While connecting the sensors to control systems etc,
environment and weather conditions; for example, make ensure adequate insulation or isolation, see IEC 60664.
sure that water cannot enter the motor or the terminal
boxes.
NOTE!
The seals of terminal boxes must be placed correctly in the Ensure the insulation level or isolation of thermistor
slots provided, to ensure the correct IP class. circuit, see IEC 60664.
3.8.1 Connections for different starting

methods 3.9 Terminals and direction
The terminal box on standard single speed motors normally
contains six winding terminals and at least one earth
of rotation
terminal. This enables the use of DOL- or Y/D –starting.
See Figure 1. The shaft rotates clockwise when viewing the shaft face at
the motor drive end, and the line phase sequence - L1, L2,
For two-speed and special motors, the supply connection L3 - is connected to the terminals as shown in Figure 1.
must follow the instructions inside the terminal box or in the
motor manual. To alter the direction of rotation, interchange any two
connections on the supply cables.
The voltage and connection are stamped on the rating
plate. If the motor has a unidirectional fan, ensure that it rotates in
the same direction as the arrow marked on the motor.
Direct-on-line starting (DOL):
Y or D winding connections may be used.
For example, 690 VY, 400 VD indicates Y-connection for

690 V and D-connection for 400 V.
Star/Delta starting (Y/D):

The supply voltage must be equal to the rated voltage of
the motor when using a D-connection.
Remove all connection links from the terminal block.
Other starting methods and severe starting

conditions:
In case other starting methods are used, such as a soft
starter, or if starting conditions are particularly difficult,
please consult ABB first.
4. Operation
4.1 Use 4.2 Cooling
The motors are designed for the following conditions unless Check that the motor has sufficient airflow. Ensure that no
otherwise stated on the rating plate. nearby objects or direct sunshine radiate additional heat to
the motor.
- Normal ambient temperature limits are -20°C to +40°C.
- Maximum altitude 1000 m above sea level. For flange mounted motors (e.g. B5, B35, V1), make sure
- Tolerance for supply voltage is ±5% and for frequency that the construction allows sufficient air flow on the outer
±2% according to EN / IEC 60034-1 (2004). surface of the flange.
The motor can only be used in applications it is intended

for. The rated nominal values and operational conditions 4.3 Safety considerations
are shown on the motor rating plates. In addition, all
The machine is intended for installation and use by qualified
requirements of this manual and other related instructions
personnel, familiar with health and safety requirements and
and standards must be followed.
national legislation.
If these limits are exceeded, motor data and construction
Safety equipment necessary for the prevention of accidents
data must be checked. Please contact ABB for further
at the installation and operating site must be provided in
information.
WARNING
WARNING
Ignoring any of given instructions or maintenance of
Do not carry out work on motor, connection cables
the apparatus may jeopardize the safety and thus
or accessories such as frequency converters,
prevents the use of the machine.
starters, brakes, thermistor cables or heating
elements when voltage is applied.
Points to observe
1. Do not step on the motor.
2. The temperature of the outer casing of the motor

may be too hot to touch during normal operation and
especially after shut-down.
3. Some special motor applications require special

instructions (e.g. using frequency converter supplies).
4. Be aware of rotating parts of the motor.
5. Do not open terminal boxes while energized.
5. Low voltage motors in variable speed operation
5.1 Introduction 5.2.3 Selection of winding insulation for

ACS800 and ACS550 converters
This part of the manual provides additional instructions for In the case of ABB ACS800-series and ACS550-series
motors used in frequency converter supply. Instructions single drives with a diode supply unit (uncontrolled DC
provided in this and respective manuals of selected voltage), the selection of winding insulation and filters can
frequency converter must be followed to ensure safety and be made according to table below:
availability of the motor.
Nominal supply Winding insulation and
Additional information may be required by ABB to decide
voltage UN of the filters required
on the suitability for some machine types used in special
converter
applications or with special design modifications.
UN ≤ 500 V ABB Standard insulation
UN ≤ 600 V ABB Standard insulation
5.2 Winding insulation + dU/dt filters
OR
Variable speed drives cause higher voltage stresses than
ABB Special insulation
the sinusoidal supply on the winding of the motor and
(variant code 405)
therefore the winding insulation of the motor as well as
UN ≤ 690 V ABB Special insulation
the filter at the converter output must be dimensioned
(variant code 405)
according following instructions.
AND
dU/dt-filters at converter
5.2.1 Phase to phase voltages output
The maximum allowed phase to phase voltage peaks at UN ≤ 690 V ABB Special insulation
the motor terminal as a function of the rise time of the pulse AND (variant code 405)
can be seen in Figure 1. cable length > 150 m
The highest curve “ABB Special Insulation” applies to For more information on resistor braking and converters
motors with a special winding insulation for frequency with controlled supply units, please contact ABB.
converter supply, variant code 405.
5.2.4 Selection of winding insulation with all
The “ABB Standard Insulation” applies to all other motors other converters
covered by this manual.
The voltage stresses must be limited below accepted limits.
5.2.2 Phase to ground voltages Please contact the system supplier to ensure the safety of
the application. The influence of possible filters must be
The allowed phase to ground voltage peaks at motor
taken into account while dimensioning the motor.
terminals are:
Standard Insulation 1300 V peak 5.3 Thermal protection

Special Insulation 1800 V peak Most of the motors covered by this manual are equipped
with PTC thermistors in the stator windings. It is
recommended to connect those to the frequency converter
by appropriate means. See also chapter 3.8.2.
5.4 Bearing currents For motors of frame size IEC 280 and upward, additional
potential equalization between the motor frame and the
Insulated bearings or bearing constructions, common driven equipment is needed, unless both are mounted on
mode filters and suitable cabling and grounding methods a common steel base. In this case, the high frequency
must be used according to the following instructions: conductivity of the connection provided by the steel
base should be checked by, for example, measuring the
potential difference between the components.
5.4.1 Elimination of bearing currents with
ABB ACS800 and ACS550 converters More information about grounding and cabling of variable
In the case of the ABB ACS800 and ACS550-series speed drives can be found in the manual “Grounding and
frequency converter with a diode supply unit, the following cabling of the drive system” (Code: 3AFY 61201998).
methods must be used to avoid harmful bearing currents in
the motors: 5.6 Operating speed
Nominal Power (Pn) Preventive measures For speeds higher than the nominal speed stated on the
and / or Frame size (IEC) motor’s rating plate or in the respective product catalogue,
Pn < 100 kW No actions needed ensure that either the highest permissible rotational speed
Pn ≥ 100 kW Insulated non-drive end of the motor or the critical speed of the whole application is
OR bearing not exceeded.
IEC 315 ≤ Frame size
≤ IEC 355 5.7 Dimensioning the motor for
Pn ≥ 350 kW
OR
Insulated non-drive end
bearing
variable speed application
IEC 400 ≤ Frame size AND 5.7.1 General
≤ IEC 450 Common mode filter at
In case of ABB’s frequency converters, the motors can
the converter
be dimensioned by using ABB’s DriveSize dimensioning
Insulated bearings which have aluminum oxide coated program. The tool is downloadable from the ABB website
inner and/or outer bores or ceramic rolling elements, (www.abb.com/motors&generators).
are recommended. Aluminum oxide coatings shall also
be treated with a sealant to prevent dirt and humidity For application supplied by other converters, the motors
penetrating into the porous coating. For the exact type of must be dimensioned manually. For more information,
bearing insulation, see the motor’s rating plate. Changing please contact ABB.
the bearing type or insulation method without ABB’s The loadability curves (or load capacity curves) are based
permission is prohibited. on nominal supply voltage. Operation in under or over
voltage conditions may influence on the performance of the
5.4.2 Elimination of bearing currents with all application.
other converters
The user is responsible for protecting the motor and driven 5.7.2 Dimensioning with ABB ACS800
equipment from harmful bearing currents. Instructions converters with DTC control
described in Chapter 5.4.1 can be used as guideline, but The loadability curves presented in Figures 4a - 4d are valid
their effectiveness cannot be guaranteed in all cases. for ABB ACS800 converters with uncontrolled DC-voltage
and DTC-control. The figures show the approximate
5.5 Cabling, grounding and EMC maximum continuous output torque of the motors as a
function of supply frequency. The output torque is given
To provide proper grounding and to ensure compliance as a percentage of the nominal torque of the motor. The
with any applicable EMC requirements, motors above 30 values are indicative and exact values are available on
kW shall be cabled by shielded symmetrical cables and request.
EMC glands, i.e. cable glands providing 360° bonding.
Also for smaller motors symmetrical and shielded cables
are highly recommended. Make the 360° grounding NOTE!
arrangement at all the cable entries as described in the The maximum speed of the motor must not be
instructions for the glands. Twist the cable shields into exceeded!
bundles and connect to the nearest ground terminal/bus
bar inside the terminal box, converter cabinet, etc.
NOTE!
Proper cable glands providing 360° bonding must
be used at all termination points, e.g. at motor,
converter, possible safety switch, etc.
5.7.3 Dimensioning with ABB ACS550 5.8 Rating plates
converters
The usage of ABB’s motors in variable speed applications
The loadability curves presented in Figures 5a - 5d are
do not usually require additional rating plates and the
valid for ABB ACS550 series converters. The figures show
parameters required for commissioning the converter can
the approximate maximum continuous output torque of
be found from the main rating plate. However, in some
the motors as a function of supply frequency. The output
special applications the motors can be equipped with
torque is given as a percentage of the nominal torque of
additional rating plates for variable speed applications and
the motor. The values are indicative and exact values are
those include following information:
available on request.
- speed range
- power range
NOTE!
- voltage and current range
The maximum speed of the motor must not be
- type of torque (constant or quadratic)
exceeded!
- converter type and required minimum switching
frequency
5.7.4 Dimensioning with other voltage
source PWM-type converters 5.9 Commissioning the variable
For other converters, which have uncontrolled DC
voltage and minimum switching frequency of 3 kHz,
speed application
the dimensioning instructions of ACS550 can be used The commissioning of the variable speed application must
as guidelines, but it shall be noted, that the actual be done according to the instructions of the frequency
thermal loadability can also be lower. Please contact the converter and local laws and regulations. The requirements
manufacturer of the converter or the system supplier. and limitations set by the application must also be taken
into account.
NOTE! All parameters needed for setting the converter must be
The actual thermal loadability of a motor may be taken from the motor rating plates. The most often needed
lower than shown by guideline curves. parameters are:
- Motor nominal voltage

5.7.5 Short time overloads - Motor nominal current
ABB motors can usually be temporarily overloaded as well - Motor nominal frequency
as used in intermittent duties. The most convenient method - Motor nominal speed
to dimension such applications is to use the DriveSize tool. - Motor nominal power
Note: In case of missing or inaccurate information, do not

operate the motor before ensuring correct settings!
ABB recommends using all the suitable protective features

provided by the converter to improve the safety of the
application. Converters usually provide features such as
(names and availability of features depend on manufacturer
and model of the converter):
- Minimum speed
- Maximum speed
- Acceleration and deceleration times
- Maximum current
- Maximum Torque
- Stall protection
6. Maintenance 6.1.1 Standby motors
If the motor is in standby for a longer period of time on
a ship or in other vibrating environment the following
measures have to be taken:
WARNING
Voltage may be connected at standstill inside the 1. The shaft must be rotated regularly every 2 weeks (to
terminal box for heating elements or direct winding be reported) by means of start up of the system. In case
heating. a start up is not possible, due to any reason, at least
the shaft has to be turned by hand in order to achieve
a different position once a week. Vibrations caused by
other vessel's equipment will cause bearing pitting which
WARNING
should be minimized by regular operation / hand turning.
The capacitor in single-phase motors can retain a
charge that appears across the motor terminals, even 2. The bearing must be greased while rotating the shaft
when the motor has reached standstill. every year (to be reported). If the motor has been
provided with roller bearing at the driven end the
transport lock to be removed before rotating the shaft.
The transport locking must be remounted in case of
WARNING transportation.
A motor with frequency converter supply may
energize even if the motor is at standstill. 3. All vibrations must be avoided to prevent a bearing from
failuring. All instructions in the motor instruction manual
for commissioning and maintenance have to be followed
additionally. The warranty will not cover the winding and
6.1 General inspection bearing damages if these instructions have not been
followed.
1. Inspect the motor at regular intervals, at least once a
year. The frequency of checks depends on, for example,
the humidity level of the ambient air and on the local 6.2 Lubrication
weather conditions. This can initially be determined
experimentally and must then be strictly adhered to.
2. Keep the motor clean and ensure free ventilation WARNING
airflow. If the motor is used in a dusty environment, Beware of all rotating parts!
the ventilation system must be regularly checked and
cleaned.
3. Check the condition of shaft seals (e.g. V-ring or radial WARNING
seal) and replace if necessary. Grease can cause skin irritation and eye
inflammation. Follow all safety precautions specified
4. Check the condition of connections and mounting and
by the manufacturer.
assembly bolts.
5. Check the bearing condition by listening for any unusual
noise, vibration measurement, bearing temperature,
Bearing types are specified in the respective product
inspection of spent grease or SPM bearing monitoring.
catalogs and on the rating plate of all motors except
Pay special attention to bearings when their calculated
smaller frame sizes.
rated life time is coming to an end.
Reliability is a vital issue for bearing lubrication intervals.
When signs of wear are noticed, dismantle the motor,
ABB uses mainly the L1-principle (i.e. that 99% of the
check the parts and replace if necessary. When bearings
motors are certain to make the life time) for lubrication.
are changed, replacement bearings must be of the same
type as those originally fitted. The shaft seals have to be
replaced with seals of the same quality and characteristics 6.2.1 Machines with permanently greased
as the originals when changing bearings.
bearings
In the case of the IP 55 motor and when the motor Bearings are usually permanently greased bearings of 1Z,
has been delivered with a plug closed, it is advisable to 2Z, 2RS or equivalent types.
periodically open the drain plugs in order to ensure that
the way out for condensation is not blocked and allows As a guide, adequate lubrication for sizes up to 250 can be
condensation to escape from the motor. This operation achieved for the following duration, according to L10.
must be done when the motor is at a standstill and has
been made safe to work on.
Duty hours for permanently greased bearings at ambient – Let the motor run for 1-2 hours to ensure that all excess
temperatures of 25 and 40° C are: grease is forced out of the bearing. Close the grease
outlet plug or closing valve if fitted.
Lubrication intervals according to L10 principle
Regreasing while the motor is at a standstill
Duty hours Duty hours If it is not possible to regrease the bearings while the
Frame size Poles at 25° C at 40° C motors are running, lubrication can be carried out while the
56-63 2-8 40 000 40 000 machine is at a standstill.
71 2 40 000 40 000 – In this case use only half the quantity of grease and then
71 4-8 40 000 40 000 run the motor for a few minutes at full speed.
80-90 2 40 000 40 000 – When the motor has stopped, apply the rest of the
80-90 4-8 40 000 40 000 specified amount of grease to the bearing.
100-112 2 40 000 32 000 – After 1-2 running hours close the grease outlet plug or
100-112 4-8 40 000 40 000 closing valve if fitted.
132 2 40 000 27 000
B. Automatic lubrication
132 4-8 40 000 40 000
160 2 40 000 36 000 The grease outlet plug must be removed permanently with
160 4-8 40 000 40 000 automatic lubrication or open closing valve if fitted.
180 2 38 000 38 000 ABB recommends only the use of electromechanical
180 4-8 40 000 40 000 systems.
200 2 27 000 27 000
200 4-8 40 000 40 000 The amount of grease per lubrication interval stated in the
225 2 23 000 18 000 table should be multiplied by four if an automatic regreasing
225 4-8 40 000 40 000 system is used.
250 2 16 000 13 000 When 2-pole motors are automatically regreased, the note
250 4-8 40 000 39 000 concerning lubricant recommendations for 2-pole motors in
Data valid at 50 Hz, for 60 Hz reduce values for 20 %. the Lubricants chapter should be followed.
These values are valid for permitted load values given in

the product catalog. Depending on application and load
6.2.3 Lubrication intervals and amounts
conditions, see the applicable product catalog or contact As a guide, adequate lubrication for motors with
ABB. regreasable bearings can be achieved for the following
duration, according to L1. For duties with higher ambient
Operation hours for vertical motors are half of the above temperatures please contact ABB. The formula to change
values. the L1 values roughly to L10 values: L10 = 2.7 x L1.
Lubrication intervals for vertical machines are half of the

6.2.2 Motors with regreasable bearings values shown in the table below.
Lubrication information plate and general lubrication The lubrication intervals are based on an ambient
advice temperature +25°C. An increase in the ambient
If the machine is equipped with a lubrication information temperature raises the temperature of the bearings
plate, follow the given values. correspondingly. The values should be halved for a 15°C
increase and may be doubled for a 15°C decrease.
On the lubrication information plate, greasing intervals
regarding mounting, ambient temperature and rotational In variable speed operation (i.e. frequency converter supply)
speed are defined. it is necessary to measure the bearing temperature for
During the first start or after a bearing lubrication a the whole duty range and if exceeds 80°C, the lubrication
temporary temperature rise may appear, approximately 10 intervals should be halved for a 15°C increase in bearing
to 20 hours. temperature. If the motor is operated at high speeds, it is
also possible to utilize so called high speed greases, see
Some motors may be equipped with a collector for old chapter 6.2.4.
grease. Follow the special instructions given for the
equipment.
WARNING
A. Manual lubrication The maximum operating temperature of the grease
and bearings, +110°C, must not be exceeded.
Regreasing while the motor is running
The designed maximum speed of the motor must
– Remove grease outlet plug or open closing valve if fitted. not be exceeded.
– Be sure that the lubrication channel is open
– Inject the specified amount of grease into the bearing.
Lubrication intervals according to L1 principle
Amount
Frame 3600 3000 1800 1500 1000 500-900
of grease kW kW kW kW
size r/min r/min r/min r/min r/min r/min
g/bearing
Ball bearings
Lubrication intervals in duty hours

112 10 all 10000 13000 all 18000 21000 all 25000 all 28000
132 15 all 9000 11000 all 17000 19000 all 23000 all 26500
160 25 ≤ 18,5 9000 12000 ≤ 15 18000 21500 ≤ 11 24000 all 24000
160 25 > 18,5 7500 10000 > 15 15000 18000 > 11 22500 all 24000
180 30 ≤ 22 7000 9000 ≤ 22 15500 18500 ≤ 15 24000 all 24000
180 30 > 22 6000 8500 > 22 14000 17000 > 15 21000 all 24000
200 40 ≤ 37 5500 8000 ≤ 30 14500 17500 ≤ 22 23000 all 24000
200 40 > 37 3000 5500 > 30 10000 12000 > 22 16000 all 20000
225 50 ≤ 45 4000 6500 ≤ 45 13000 16500 ≤ 30 22000 all 24000
225 50 > 45 1500 2500 > 45 5000 6000 > 30 8000 all 10000
250 60 ≤ 55 2500 4000 ≤ 55 9000 11500 ≤ 37 15000 all 18000
250 60 > 55 1000 1500 > 55 3500 4500 > 37 6000 all 7000
2801) 60 all 2000 3500 - - - - - - -
2801) 60 - - - all 8000 10500 all 14000 all 17000
280 35 all 1900 3200 - - - -
280 40 - - all 7800 9600 all 13900 all 15000
315 35 all 1900 3200 - - - -
315 55 - -
all 5900 7600 all 11800 all 12900
355 35 all 1900 3200 - - - -
355 70 - -
all 4000 5600 all 9600 all 10700
400 40 all 1500 2700 - - - -
400 85 - - all 3200 4700 all 8600 all 9700
450 40 all 1500 2700 - - - -
450 95 - - all 2500 3900 all 7700 all 8700
Roller bearings
Lubrication intervals in duty hours

160 25 ≤ 18,5 4500 6000 ≤ 15 9000 10500 ≤ 11 12000 all 12000
160 25 > 18,5 3500 5000 > 15 7500 9000 > 11 11000 all 12000
180 30 ≤ 22 3500 4500 ≤ 22 7500 9000 ≤ 15 12000 all 12000
180 30 > 22 3000 4000 > 22 7000 8500 > 15 10500 all 12000
200 40 ≤ 37 2750 4000 ≤ 30 7000 8500 ≤ 22 11500 all 12000
200 40 > 37 1500 2500 > 30 5000 6000 > 22 8000 all 10000
225 50 ≤ 45 2000 3000 ≤ 45 6500 8000 ≤ 30 11000 all 12000
225 50 > 45 750 1250 > 45 2500 3000 > 30 4000 all 5000
250 60 ≤ 55 1000 2000 ≤ 55 4500 5500 ≤ 37 7500 all 9000
250 60 > 55 500 750 > 55 1500 2000 > 37 3000 all 3500
2801) 60 all 1000 1750 - - - - - - -
2801) 70 - - - all 4000 5250 all 7000 all 8500
280 35 all 900 1600 - - - -
280 40 - - all 4000 5300 all 7000 all 8500
315 35 all 900 1600 - - - -
315 55 - -
all 2900 3800 all 5900 all 6500
355 35 all 900 1600 - - - -
355 70 - -
all 2000 2800 all 4800 all 5400
400 40 all - 1300 - - - -
400 85 - - all 1600 2400 all 4300 all 4800
450 40 all - 1300 - - - -
450 95 - - all 1300 2000 all 3800 all 4400
1) M3AA
For motors M4BP 160 to 250 the interval may be increased by 30 %, up to a maximum of three calendar years.
The values in table above are valid also for sizes M4BP 280 to 355.
6.2.4 Lubricants The following high performance greases can be used:
- Esso Unirex N2 or N3 (lithium complex base)

WARNING - Mobil Mobilith SHC 100 (lithium complex base)
Do not mix different types of grease. - Shell Gadus S5 V 100 2 (lithium complex base)
Incompatible lubricants may cause bearing damage. - Klüber Klüberplex BEM 41-132 (special lithium
base)
- FAG Arcanol TEMP110 (lithium complex base)
When regreasing, use only special ball bearing grease with - Lubcon Turmogrease L 802 EP PLUS
the following properties: (special lithium base)
– good quality grease with lithium complex soap and with - Total Multiplex S 2 A (lithium complex base)
mineral- or PAO-oil
– base oil viscosity 100-160 cST at 40°C NOTE!
– consistency NLGI grade 1.5 - 3 *) Always use high speed grease for high speed 2-pole
– temperature range -30°C - +120°C, continuously. machines where the speed factor is higher than
*) For vertical mounted motors or in hot conditions a stiffer 480,000 (calculated as Dm x n where Dm = average
end of scale is recommended. bearing diameter, mm; n = rotational speed, r/min).
The high speed grease is also used in motor types
The above mentioned grease specification is valid if the M2CA, M2FA, M2CG and M2FG, frame sizes 355 to
ambient temperature is above -30°C or below +55°C, and 400 2-pole machines.
the bearing temperature is below 110°C; otherwise consult
ABB regarding suitable grease.
Grease with the correct properties is available from all the The following greases can be used for high speed cast iron
major lubricant manufacturers. motors but not mixed with lithium complex greases:
Admixtures are recommended, but a written guarantee - Klüber Klüber Quiet BQH 72-102 (polyurea base)
must be obtained from the lubricant manufacturer, - Lubcon Turmogrease PU703 (polyurea base)
especially concerning EP admixtures, that admixtures do If other lubricants are used;
not damage bearings or the properties of lubricants at the
operating temperature range. Check with the manufacturer that the qualities correspond
to those of the above mentioned lubricants. The lubrication
interval are based on the listed high performance greases
WARNING above. Using other greases can reduce the interval.
Lubricants containing EP admixtures are not
recommended in high bearing temperatures in frame If the compatibility of the lubricant is uncertain, contact
sizes 280 to 450. ABB.
7. After Sales Support
7.1 Spare parts

When ordering spare parts, the motor serial number, full
type designation and product code, as stated on the rating
plate, must be specified.
For more information, please visit our web site

www.abb.com/partsonline.
7.2 Rewinding
Rewinding should always be carried out by qualified repair
shops.
Smoke venting and other special motors should not be

rewound without first contacting ABB.
7.3 Bearings
Special care should be taken with the bearings. These
must be removed using pullers and fitted by heating or
using special tools for the purpose.
Bearing replacement is described in detail in a separate

instruction leaflet available from the ABB Sales Office.
8. Environmental requirements
8.1 Noise levels

Most of ABB’s motors have a sound pressure level not
exceeding 82 dB(A) at 50 Hz .
Values for specific machines can be found in the relevant

product catalogues. At 60 Hz sinusoidal supply the values
are approximately 4 dB(A) higher compared to 50 Hz
values in product catalogues.
For sound pressure levels at frequency converter supply,

please contact ABB.
Sound pressure levels for all machines having separate

cooling systems and for series M2F*/M3F*, M2L*/M3L*,
M2R*/M3R*, M2BJ/M3BJ and M2LJ/M3LJ are indicated in
separate additional manuals.
9. Troubleshooting
These instructions do not cover all details or variations in equipment nor provide for every possible condition to be met in
connection with installation, operation or maintenance. Should additional information required, please contact the nearest
ABB Sales Office.
Motor troubleshooting chart

Your motor service and any troubleshooting must be handled by qualified persons who have proper tools and equipment.
TROUBLE CAUSE WHAT TO DO

Motor fails to start Blown fuses Replace fuses with proper type and rating.
Overload trips Check and reset overload in starter.
Improper power supply Check to see that power supplied agrees with motor rating plate and
load factor.
Improper line connections Check connections against diagram supplied with motor.
Open circuit in winding or control switch Indicated by humming sound when switch is closed. Check for loose
wiring connections.
Also ensure that all control contacts are closing.

Mechanical failure Check to see if motor and drive turn freely. Check bearings and
lubrication.
Short circuited stator Indicated by blown fuses. Motor must be rewound. Remove end
Poor stator coil connection shields, locate fault.
Rotor defective Look for broken bars or end rings.
Motor may be overloaded Reduce load.
Motor stalls One phase may be open Check lines for open phase.
Wrong application Change type or size. Consult equipment supplier.
Overload Reduce load.
Low voltage Ensure the rating plate voltage is maintained. Check connection.
Open circuit Fuses blown, check overload relay, stator and push buttons.
Motor runs and Power failure Check for loose connections to line, to fuses and to control.
then dies down
Motor does Not applied properly Consult equipment supplier for proper type.
not come up to Voltage too low at motor terminals Use higher voltage or transformer terminals or reduce load. Check
nominal speed because of line drop connections. Check conductors for proper size.
Starting load too high Check the start load of the motor.
Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may be required, as repairs
are usually temporary.
Open primary circuit Locate fault with testing device and repair.
TROUBLE CAUSE WHAT TO DO
Motor takes too long to Excessive load Reduce load.
accelerate and/or draws Low voltage during start Check for high resistance. Make sure that adequate cable
high current size is used.
Defective squirrel cage rotor Replace with new rotor.
Applied voltage too low Correct power supply.
Wrong rotation direction Wrong sequence of phases Reverse connections at motor or at switchboard.
Motor overheats while Overload Reduce load.
running Frame or ventilation openings may Open vent holes and check for a continuous stream of air
be full of dirt and prevent proper from the motor.
ventilation of motor
Motor may have one phase open Check to make sure that all leads are well connected.
Grounded coil Motor must be rewound
Unbalanced terminal voltage Check for faulty leads, connections and transformers.
Motor vibrates Motor misaligned Realign.
Weak support Strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearings not in line Repair motor.
Balancing weights shifted Rebalance motor.
Contradiction between balancing of Rebalance coupling or motor.
rotor and coupling (half key - full key)
Polyphase motor running single phase Check for open circuit.
Excessive end play Adjust bearing or add shim.
Scraping noise Fan rubbing end shield or fan cover Correct fan mounting.
Loose on bedplate Tighten holding bolts.
Noisy operation Air gap not uniform Check and correct end shield fits or bearing fits.
Rotor unbalance Rebalance rotor.
Hot bearings Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away from shaft shoulder Move pulley closer to motor bearing.
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of the drive.
Insufficient grease Maintain proper quality and amount of grease in bearing.
Deterioration of grease or lubricant Remove old grease, wash bearings thoroughly in kerosene
contaminated and replace with new grease.
Excess lubricant Reduce quantity of grease, bearing should not be more than
half full.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, clean housing thoroughly first.
Figure 1. Connection diagram
Bild 1. Anschlußdiagram
Figure 1. Connection
Figura 1. Conexión
Figura 1. Collegamento
Figura 1. Diagrama de ligações
Figur 1. Anslutningdiagramm
Kuva 1. Kytkentäkaavio
Figure 2. Belt drive

Bild 2. Riementrieb
Figure 2. Glissières et entraînements à courroie
Figure 2. Carriles tensores y correas
Figura 2. Slitte tendicinghia e pulegge
Figura 2. Transmissão por correias
Figur 2. Remdrift
Kuva 2. Hihnakäyttö
Low voltage motor manual 01-2009 | ABB Motors and Generators 155
Figure 3. Mounting of half-coupling or pulley
Bild 3. Anbau von Kupplungshälften und Riemenscheiben
Figure 3. Montage des demi-accouplements et des poulies
Figura 3. Montaje de mitades de acoplamiento y poleas
Figura 3. Montaggio di semigiunti e pulegge
Figura 3. Montagem de meio acoplamento ou poleia
Figur 3. Montering av kopplinshalvor och drivskivor
Kuva 3. Kytkinpuolikkaan ja hihnapyörän asennus
Loadability curves with ACS800 converters with DTC control
Belastbarkeitskurven für ACS800-Frequenzumrichter mit DTC-Steuerung
Courbes de capacité de charge avec convertisseurs ACS800 et commande DTC
Curvas de capacidad de carga con convertidores ACS800 dotados de control DTC
Curve di caricabilità con convertitori ACS800 e controllo DTC
Curvas de capacidade de carga com conversores ACS800 com controlo de transmissão digital (DTC)
Lastbarhetskurvor för ACS800-omriktare med DTC-styrning
Kuormitettavuuskäyrät DTC-säädöllä varustetuille ACS800-taajuusmuuttajille
Figures/Abbildungen/Figures/Figure/Figure/Figuras/Figur/Kuvat 4a, 4b, 4c, 4d
Low voltage motors, nominal frequency of the motors 50/60 Hz, temperature rise B/F
Niederspannungsmotoren, Nennfrequenz der Motoren 50/60 Hz, Temperaturanstieg B/F
Moteurs à basse tension, fréquence nominale des moteurs de 50/60 Hz, augmentation de température B/F
Motores de baja tensión, frecuencia nominal de los motores 50/60 Hz, aumento de temperatura B/F
Motori a bassa tensione, frequenza nominale dei motori 50/60 Hz, incremento di temperatura B/F
Motores de baixa tensão, frequência nominal dos motores 50/60 Hz, aumento da temperatura B/F
Lågspänningsmotorer, märkfrekvens för motorerna 50/60 Hz, temperaturstegring B/F
Pienjännitemoottorit, moottorin nimellistaajuus 50/60 Hz, lämpötilan nousu B/F
4a ACS800/50 Hz, Temperature rise B 4b ACS800/60 Hz, Temperature rise B
T/TN (%) T/TN (%)

120 120
Separate cooling Separate cooling
100 100
80 80
Sizes Sizes
80-132 80-132
60 60
Sizes Sizes
160-450 160-450
40 40
0 0
0 20 40 60 80 100 0 20 40 60 80 100 120
Frequency (Hz) Frequency (Hz)
4c ACS800/50 Hz, Temperature rise F 4d ACS800/60 Hz, Temperature rise F
T/TN (%) T/TN (%)

120 120
100 100
Sizes Sizes
80-132 80-132
80 80
Sizes Sizes
160-450 160-450
60 60
40 40
0 0
0 20 40 60 80 100 0 20 40 60 80 100 120
Low voltage motor manual 01-2009 | ABB Motors and Generators 157
Loadability curves with ACS550 converters
Belastbarkeitskurven für ACS550-Frequenzumrichter
Courbes de capacité de charge avec convertisseurs ACS550
Curvas de capacidad de carga con convertidores ACS550
Curve di caricabilità con convertitori ACS550
Curvas de capacidade de carga com conversores ACS550
Lastbarhetskurvor för ACS550-omriktare
Kuormitettavuuskäyrät ACS550-taajuusmuuttajille
Figures/Abbildungen/Figures/Figure/Figure/Figuras/Figur/Kuvat 5a, 5b, 5c, 5d
Low voltage motors, nominal frequency of the motors 50/60 Hz, temperature rise B/F
Niederspannungsmotoren, Nennfrequenz der Motoren 50/60 Hz, Temperaturanstieg B/F
Moteurs à basse tension, fréquence nominale des moteurs de 50/60 Hz, augmentation de température B/F
Motores de baja tensión, frecuencia nominal de los motores 50/60 Hz, aumento de temperatura B/F
Motori a bassa tensione, frequenza nominale dei motori 50/60 Hz, incremento di temperatura B/F
Motores de baixa tensão, frequência nominal dos motores 50/60 Hz, aumento da temperatura B/F
Lågspänningsmotorer, märkfrekvens för motorerna 50/60 Hz, temperaturstegring B/F
Pienjännitemoottorit, moottorin nimellistaajuus 50/60 Hz, lämpötilan nousu B/F
5a ACS550/50 Hz, Temperature rise B 5b ACS550/60 Hz, Temperature rise B
T/TN (%) T/TN (%)

120 120
100 100
80 80
Sizes Sizes
80-132 80-132
60 60
Sizes Sizes
160-450 160-450
40 40
0 0
0 20 40 60 80 100 0 20 40 60 80 100 120
5c ACS550/50 Hz, Temperature rise F 5d ACS550/60 Hz, Temperature rise F
T/TN (%) T/TN (%)
120 120
100 100
Sizes Sizes
80-132 80-132
80 80
Sizes Sizes
160-450 160-450
60 60
40 40
0 0
0 20 40 60 80 100 0 20 40 60 80 100 120
Figure/Bild/Figure/Figura/Figura/Figura/Figur/Kuva 6.
Allowed phase to phase voltage peaks at motor terminal as a function of rise time.
..... ABB Special Insulation; ___ ABB Standard Insulation
Zulässige Phase-zu-Phase-Spannungsspitzen an Motorklemmen als Funktion der Anstiegszeit.
..... ABB Spezialisolierung; ___ABB Standardisolierung
Pics de tension phase-phase au niveau des bornes du moteur en tant que fonction de temps de hausse.
..... ABB Isolation spéciale ; ___ Isolation standard ABB
Picos de tensión permitidos entre fases en los bornes del motor en función del tiempo de aumento.
..... Aislamiento especial de ABB; ___ Aislamiento estándar de ABB
Picchi di tensione da fase a fase ammessi ai morsetti del motore in funzione del tempo di salita.
..... Isolamento speciale ABB; ___ Isolamento standard ABB
Fase permitida para picos de tensão de fase no terminal do motor como função do tempo de subida.
..... Isolamento especial da ABB; ___ Isolamento normal da ABB
Tillåtna fas till fas-spänningsstoppar vid motoranslutningarna som en funktion av stigtid.
..... ABB Specialisolering; ___ ABB Standardisolering
Pääjännitteiden suurimmat sallitut piikkiarvot nousunopeuden funktiona.
..... ABB:n erikoiseristys; ___ ABB:n vakioeristys
2,20
2,00
1,80
Peak voltage ULL, kV
1,60
1,40
1,20
ABB Special Insul.
1,00
ABB Standard Insul.
0,80
0,00 0,20 0,40 0,60 0,80 1,00 1,20
Rise time 10-90 %, µs
Contact us
9AKK104570 ML 01-2009 Rev D, 3GZF500730-85 Rev D

www.abb.com/motors&generators © Copyright 2010 ABB
All rights reserved
Specifications subject to change without notice.
Betriebsanleitung 9X0
Instructions de service Picostat
Instructions
Massbilder / Cotes d'encombrement / Dimensions
Stecker / Connecteur / Plug Stecker / Connecteur / Plug

DIN 43650-A DIN 43650-A (GL)
( Zubehör 58 / Accessoire 58 / Accessory 58 ) ( Zubehör 59 / Accessoire 59 / Accessory 59 )
Elektrischer Anschluss / Raccordement électrique / Electrical connection
2 1 3
DIN 43650-A DIN 43650-A (GL)
Schalter 20 AC 250 V 10 (2) A Schalter 28 AC 250 V 5 (1) A Schalter 83 AC 30 V 0.3 (0.2)A

Microrupteur 20 Microrupteur 28 Microrupteur 83
DC 220 V 0.3 (0.2)A DC 220 V 0.3 (0.2)A DC 75 V 0.16 (0.1)A
Microswitch 20 Microswitch 28 Microswitch 83
110 V 0.5 (0.3)A 110 V 0.5 (0.3)A 30 V 0.3 (0.2)A
24 V 10 (4) A 24 V 5 (4) A
Lebensdauer mechanisch (Anzahl Lastspiele) Schalter 20 Schalter 28/83

Durée de vie mechanique (Nombre de cycles) Microrupteur 20 1 Mio. Microrupteur 28/83 10 Mio.
Mechanical life time (Number of cycles) Microswitch 20 Microswitch 28/83
Betriebstemperatur / Température de service / Operating temperature
Type 9B0, 9K0 – 25°C ... + 85°C

Type 9M0 0°C ... + 80°C
Messstoff-Temperatur / Température de médium / Medium temperature

Type 9B0, 9K0 – 25°C ... + 120°C
Type 9M0 0°C ... + 80°C
Lagertemperatur / Température de stockage / Storage temperature

– 40°C ... + 80°C
Trafag AG
CH-8708 Männedorf
Tel. +41 1 922 32 32
Fax +41 1 922 32 33
e–mail trafag@trafag.com
Internet www.trafag.com
Betriebsdruck / Pression de functionnement / Operating pressure
Messbereich / Plage / Range -0.6...3.4 0...4 0...6 1...10 1...16 2...25 4...40 6...60 10...100 16...160 25...250
Balg Schaltdiff. Schalter 20 ca. 1

) 0.3 0.3 0.3 0.7 0.7 1.6 1.6
Soufflet Schaltdiff. Schalter 28/83 ca. 2
) 0.2 0.2 0.2 0.5 0.5 1.2 1.2
Bellow Höchstzul. Betriebsdruck 3
) 12 12 12 24 24 40 40
Messbereich / Plage / Range 1...10 1...16 2...25 4...40 6...60 10...100 16...160 25...250 40...400
Membrane Schaltdiff. Schalter 20/28/83 ca.*) 0.4...1.7 0.4...1.7 1.2...4.5 1.2...4.5 4...16 4...16
Höchstzul. Betriebsdruck 200 200 200 200 200 200
*)
Kolben Schaltdiff. Schalter 20/28/83 ca. 0.8...2.4 0.8...2.4 2...6 2...6 5...15 5...15 12...40 12...40 12...50
Piston Höchstzul. Betriebsdruck 100 100 100 100 200 200 400 400 600
*) Schaltdiff. abhängig vom eingestellten Sollwert / Différentiel en fonction de la valeur de consigne / Switching differential depending upon the
preset value
1
) Schaltdiff. Schalter 20 ca. / Différentiel suivant type de microrupteur 20 env. / Switching differential switch 20 approx.
2
) Schaltdiff. Schalter 28/83 ca. / Différentiel suivant type de microrupteur 28/83 env. / Switching differential switch 28/83 approx.
3
) Höchstzul. Betriebsdruck / Pression maximum admissible / Maximum working pressure
Druckanschluss / Raccord de pression / Pressure connection
1) Anziehdrehmoment:
G 1/8": MA = 16 ... 20Nm
Couple de serrage:
Torque moment: G 1/4": MA = 32 ... 40Nm
2) O-Ring:
Joint torique: ø 6.75x1.78
2) O-ring seal:
o
≥ 250 bar Nitril 90 Shore
o
< 250 bar Nitril 70 Shore
3)
3) Befestigungs-Schraube:
Vis de fixation: M5
Druckanschluss 1) Fastening screw:
Raccord de pression
Pressure connection 1) Festigkeitsklasse:
Classe de résistance: 8.8
Property class:
Anziehdrehmoment:
H73202b Trafag AG 99/02

Couple de serrage: 4.5 ... 6Nm
Mounting torque:
Achtung / Attention / Attention Sollwert-Einstellung / Adjustage de la valeur de consigne / Preset value adjustment
1.
entfernen
enlever
remove We reserve the right to make alternations as technical progress may warrant.
H: Hysterese abhängig vom

eingestellten Sollwert.
H: Hystérésis dépendante de la
valeur de consigne.
H: Hysteresis depending upon the

preset value.
2.
H
t
2
1
3 t
Trafag AG
CH-8708 Männedorf
Tel. +41 1 922 32 32
Fax +41 1 922 32 33
e–mail trafag@trafag.com
Internet www.trafag.com
Installation & Instruction Leaflet
IP2044/GEA
December 2006 Vibrating Fork
Vibrating Fork
Important safety notice
GB
Protection afforded by compliance to EN61010-1 (2001) may be impaired if the equipment is not used as specified.
Vibrating Fork is a liquid level switch. It must be installed, connected, commissioned, operated and maintained by
suitably qualified personnel only, observing any national and local requirements that may apply.
Note Importante
F
La sécurité selon la norme EN610100-1 (2001) pourra être réduite si les conseils dans ce manuel ne sont pas suivis.
Vibrating Fork est un détecteur de niveau de liquide conçu pour une utilisation en dehors de zones classées
dangereuses. Vibrating Fork doit être installé, raccordé, mis en service, utilisé, et entretenu par des personnes
convenablement qualifiées qui respectent des normes locales et nationales.
Wichtiger Sicherheitshinweis:
D
Wenn die Geräte nicht wie spezifiziert verwendet werden, kann der Schutz gemäß EN610100-1 (2001) beeinträchtigt
werden.
Vibrating Fork ist ein Flüssigkeitsstandschalter zur Verwendung im Ex-freien Bereich. Vibrating Fork muss durch
geeignetes Personal installiert, angeschlossen, betrieben und gewartet werden. Dabei sind nationale und lokale
Bestimmungen zu beachten.
Viktig information om säkerhet:

S
Personskydd i enlighet med EN610100-1 (2001) kan minska eller upphöra om nivåvakten inte brukas enligt denna
instruktion
Vibrating Fork är en nivåvakt för vätskor. Den får endast installeras i icke explosionsfarliga miljöer. Vibrating Fork får
endast installeras, elektriskt inkopplas, driftsättas och underhållas av härför tekniskt kvalificerad personal med
beaktande av nationella och lokala tillämpliga bestämmelser.
Atención
E
Protección según EN610100-1 (2001), Se reducirá si el equipo no se utiliza según especificación.
El Vibrating Fork es un interruptor de nivel diseñado para trabajar fuera de zonas clasificadas peligrosas. El Vibrating
Fork debe instalarse, conectarse, ponerse en marcha, operarse y mantenerse por personal cualificado, teniendo en
cuenta todas las reglamentaciones nacionales y locales vigentes.
Belangrijke veiligheidsnota.
NL
De protectie conform aan de directieve EN610100-1 (2001) kan vervallen wanneer het product niet wordt toegepast
zoals beschreven.
De Vibrating Fork is ontworpen om gebruikt te worden in niet- explosiegevaarlijke ruimten. De Vibrating Fork dient
uitsluitend geplaatst, aangesloten, in bedrijf gesteld en onderhouden te worden door bevoegd personeel, en de
nationale voorschriften dienen gerespecteerd te worden.
PL Uwaga dotycząca bezpieczeństwa.

Zabezpieczenia w konstrukcji urządzenia wykonane zgodnie z normą EN610100-1 (2001) mogą być
niewystarczające o ile urządzenie jest użytkowane niezgodnie ze specyfikacją.
Vibrating Fork jest sygnalizatorem poziomu cieczy. Musi być instalowany, podłączony, użytkowany i serwisowany tylko
przez wykwalifikowany personel, posiadający wymagane uprawnienia.
Page 2
GB CAUTION: REFER TO MANUAL
F ATTENTION: CONSULTER LE MANUEL
D VORSICHT: HANDBUCH BEACHTEN
S VARNING: SE INSTRUKTIONEN
E PRECAUCIÓN: VER MANUAL
NL AANDACHT: RAADPLEEG DE FOLDER
PL UWAGA: PATRZ INSTRUKCJA
THE EXTERNAL SURFACE MAY BE HOT. CARE MUST BE TAKEN TO AVOID

GB
POSSIBLE BURNS.
LA SURFACE EXTERNE PEUT ETRE CHAUDE. ATTENTION AU RISQUE EVENTUEL

F
DE BRULURE.
DIE OBERFLÄCHE DES GERÄTS KANN VON AUßEN HEIß SEIN. BITTE VORSICHT,
D
UM VERBRENNUNGEN ZU VERMEIDEN.
S VARNING: VARM YTA, SE TILL ATT DU INTE BRÄNNER DIG
LA SUPERFICIE EXTERNA PUEDE ESTAR CALIENTE. DEBE TENERSE EN CUENTA

E
PARA EVITAR POSIBLES QUEMADURAS.
DE EXTERNE OPPERVLAKTE KAN HEET ZIJN.DE ZORG MOET WORDEN GENOMEN

NL
OM MOGELIJKE BRANDWONDEN TE VERMIJDEN.
ZEWNĘTRZNA POWIERZCHNIA MOŻE BYĆ GORĄCA, DLATEGO NALEŻY

PL
ZACHOWAĆ OSTROŻNOĆ ABY SIĘ NIE POPARZYĆ.
Page 3
THE PROTECTIVE EARTH TERMINAL MUST BE CONNECTED TO AN EXTERNAL
GB
PROTECTIVE EARTHING SYSTEM.
LA BORNE DE MISE A LA TERRE DOIT ETRE RELIEE A LA TERRE DU RESEAU

F
ELECTRIQUE.
DER EXTERNER ERDANSCHLUSS MUSS AN EINE SEPARATE ERDE

D
ANGESCHLOSSEN WERDEN.
S SKYDDSJORDANSLUTNINGEN MÅSTE DRAS TILL EXTERN SKYDDSJORD
E EL TERMINAL DE PUESTA A TIERRA DEBE CONECTARSE A LA RED DE TIERRAS.
DE BESCHERMENDE TERMINAL EARTH MOET AAN HET EXTERNE

NL
BESCHERMENDE AANAARDEN WORDEN AANGESLOTEN SYSTEEM.
OCHRONNY ZACISK UZIEMIENIA MUSI BYĆ PODŁĄCZONY Z ZEWNĘTRZNYM

PL
UZIEMIENIEM SYSTEMU.
Page 4
GB Handling
F Manipulation
D Handhabung
S Hantering
E Manejo Do not hold Vibrating Fork by forks.

Ne pas tenir le Vibrating Fork par les lames.
Vibrating Fork nicht an der Stimmgabel halten.
Håll ej Vibrating Fork i gaffeln.
NL Behandeling
No sujetar el Vibrating Fork por las horquillas
De Vibrating Fork mag niet aan de vorken vastgehouden worden.
Nie przenosić Vibrating Fork za widełki.
PL Obsługa
Device Identification
GB PNP solid state output
models : dc low voltage
Identification
F Modèle à sortie PNP: faible
intensité cc
Typenschild
D PNP Transistorausgang:
Niederspannung DC
Produktidentifiering
S Modell med PNP
transistorutgång max 60V dc
Identificación del equipo
E Modelos con salida PNP:
baja intensidad cc
Identificatie van het toestel
NL Model met PNP-uitgang:zwakke
dc intensiteit
PL Identyfikacja urządzenia.
Wyjście PNP: dc
Page 5
Page 6
GB Mounting examples
F Exemples de montage
D Montagebeispiele
S Exempel på montering
E Ejemplos de montaje
NL Montagewoorbeelden
PL Przykłady motażu
SP Switchpoint
GB
HY Switching hysteresis
SP Point de détection (pour de l’eau)

F
HY Hystérésis
SP Schaltpunkt
D
HY Schalthysterese
SP Omkopplingspunkt
S
HY Omkopplingspunkt Hysteres
SP Punto de conmutación
E
HY Histéresis
SP Schakelpunt
NL
HY Hysteresis
SP Punkt przełączania
PL
HY Histereza
Page 7
Avoid product build-up GB
Eviter des dépôts de matières

F
solides
Produktablagerungen
D
vermeiden
Undvik uppbyggnad av
S
beläggningar
Evitar el almacenamiento de
E
producto
Vermijd productaanladingen NL
Zabopieganie zarastaniu czujnika PL
Do not alter Vibrating Fork in

GB
any way
Ne modifier, en aucune manière,

F
la forme des lames.
Vibrating Fork in keiner Weise

D
verändern.
Vibrating Forks gaffelblad får

inte böjas eller vinklas i någon S
riktning
No debe modificarse la forma de

E
las láminas en ningun caso
In elk geval mag de Vibrating

NL
Fork niet beschadigd worden
Nie modyfikować Vibrating Forka

PL
w żaden sposób
Page 8
GB Installation ¾” BSPT, NPT
1” BSPT (R1)
PTFE
F Installation (Teflon)
D Installation
S Installation 1” BSPP (G1)

Gasket
Joint
E Dichtung
Instalación
Packning
Junta
Dichting
NL Installatie Uszczelnienie
PL Instalacja
51mm Tri-clover
(ISO2852)
Seal (supplied in SK266)

Joint (fourni dans SK266)
Dichtung (enthalten in SK266)
Packning (levereras med SK266)
Junta (suministrada en SK266)
Dichting (geleverd met SK266)
Uszczelka (dostarczana z SK266)
Page 9
Correct fork alignment GB
Orientation correcte de
F
la fourche
Richtige
D
Sensorausrichtung
Korrekt gaffelläge S
Alineación correcta de la
E
horquilla
Correcte orientatie van

NL
de vork
Prawidłowe usytuowanie
PL
widełek
Alignment groove
Repère pour orienter la fourche
Ausrichtung
Indikeringsspår för gaffelläge
Marca para alineación
Een inkeping duidt de orientatie
van de vork
Rowek ustawienia
Note
Noter l’orientation de la fourche
Beachten
OBS ! “spåret”
Nota
Uwaga
Page 10
Important safety notice
GB
Ensure wiring is suitable for the load current and the insulation is suitable for the voltage, temperature and
environment of the installation
A supply disconnection device must be included in the installation, fitted as a close as practical and not
obstructed by the equipment. It must be double pole and marked as the disconnection device.
Disconnect supply before removing connector
F Note Importante
Le type de câble doit convenir à la tension d'alimentation, au courant consommé et à la température de

service.
Un coupe-circuit doit être compris dans le circuit, monté près du détecteur et facile d'accés. Il doit être
double pôle et repéré clairement.
Couper l'alimentation avant d'ôter le connecteur du détecteur.
Wichtiger Sicherheitshinweis:
D
Bitte sicherstellen, dass die Kabel für die Stromlast geeignet sind und dass die Isolierung der Spannung,
Termperatur und Umgebung angemessen ist.
Bei der Installation muss ein Trennschalter so nahe wie möglich am Schalter und jederzeit erreichbar
angebracht werden. Er muss zweipolig sein und als Trennschalter gekeinnzeichnet sein.
Bitte Strom abschalten, bevor der Anschlussstecker gezogen wird.
Viktig information om säkerhet:

S
Säkerställ att kabel med lämplig area och isolering för aktuell ström, spänning, temperatur och miljö används.
Installationen måste vara försedd med en tvåpolig arbetsbrytare så nära utrustningen som det är praktiskt
möjligt. Brytaren skall vara tydligt uppmärkt.
Bryt spänningen innan du tar bort kabelkontakten
E Atención
Asegurarse que los cables son los adecuados para la carga a soportar y el aislamiento de los mismos para el
voltaje, confirmar las temperaturas y las condiciones de ambiente en la instalación
Un elemento suplementario de desconexión debe ser incluido en la instalación, situado tan cerca como sea
posible y que no pueda quedar obstruido. Debe ser de doble polaridad y marcado como elemento de
desconexión.
Desconectar el suministro eléctrico antes de cambiar el conector.
NL Belangrijke veiligheidsinstructie
Verzeker u ervan dat de bedrading geschikt is voor de belastingsstroom en de isolatie

aangepast aan de spanning, de temperatuur en de omgeving van de installatie.
Een voedings – afschakelelement dient te worden voorzien in de installatie en zo dicht als maar praktisch
mogelijk bij het instrument geplaatst, zonder door dit laatste gehinderd te zijn.
Schakel de voeding af vooraleer de connector te verwijderen.
PL
Uwaga dotycząca bezpieczeństwa
Należy zapewnić odpowiedni prąd obciążenia i izolacje przewodów odpowiednią dla napięcia, temperatury i
warunków montażu.
Elektryczna linia zasilająca musi być wyposażona w odpowiednie zabezpieczenie, zamontowane zgodnie z
zasadami wymaganymi przy tego typu instalacjach. Zabezpieczenie powinno być podłączone i wyraźnie
oznaczone na obiekcie.
Odłącz zasilanie przed demontażem złącza.
Page 11
GB Mode selection Load switching: ac/dc PNP output: dc
Direct load switching: ac/dc PNP for PLC/SPS connection: dc

Commutation de charge ca/cc PNP pour automate: cc
F Choix de commutation Zweileiterschalter: AC/DC PNP für SPS- Anschluss: DC
Lastbrytare ac/dc PNP transistorutgång till PLC: dc
Commutación carga : ca/cc PNP para conexion a PLC: dc
D Funktionswahl ac/dc belastingsverandering PNP voor aansluiting aan een:cc
Wyjście z bezpośrednim obciążeniem: PLC/SPS : dc
ac/dc Wyjście PNP dla PLC: dc
S Funktionsval
Selección modo
E
conmutación
NL Functieselectie
PL Wybór trybu pracy
Direct load Switching PNP output
PE (Ground / Terre ou masse / Erde / PE (Ground / Terre ou masse / Erde /

Skyddsjord / Aarding / Tierra ò masa / Skyddsjord / Aarding / Tierra ò masa /
Uziemienie) Uziemienie)
DRY = ON: High level alarm

SEC = Passant : pour alarme de
niveau haut
TROCKEN = EIN: Anwendung als
oberer Begrenzer
TORR = TILL: Högnivålarm
SECO - ON : Alarma nivel alto
DROOG = AAN : Hoog niveau alarm
DRY = ON: Alarm wysokiego
poziomu
PE (Ground / Terre ou masse / Erde / PE (Ground / Terre ou masse / Erde /

Skyddsjord / Aarding / Tierra ò masa / Skyddsjord / Aarding / Tierra ò masa /
Uziemienie) Uziemienie)
WET = ON: Low level alarm

MOUILLE = Passant : pour alarme de
niveau bas
NASS = EIN: Unterer Begrenzer
(Mangelsicherung)
VÅT = TILL: Lågnivålarm
HUMEDO = ON Alarma nivel bajo
NAT = AAN : Laag niveau alarm
WET = ON: Alarm niskiego poziomu
Page 12
Selección modo
E Mode selection GB
conmutación
NL Functieselectie Choix de commutation F
PL Wybór trybu pracy Funktionswahl D
Funktionsval S
Load switching: ac/dc PNP output: dc

Direct load switching: ac/dc Solid state PNP output: dc
Commutation de charge ca/cc Sortie PNP: cc
Zweileiterschalter: AC/DC PNP Transistor Ausgang: DC
Lastbrytare ac/dc PNP transistorutgång: dc
Commutación carga : ca/cc Salida PNP : cc
ac/dc belastingsverandering PNP uitgang : dc
Wyjście z bezpośrednim obciążeniem: ac/dc Wyjście PNP dla PLC: dc
GB R = external load (must be wired) = external load
Max. inrush current: 5A (electrically protected)

I Max continuous: I Load off : <3mA
I Min: 20mA I Max continuous: 500 mA
I Load off: <3mA
F R = Charge dans la boucle (obligatoire.) = Charge externe
Courant d’entrée maxi: 5A (limiteur interne)

Courant maxi de maintien: 500mA
I Maxi continu: 500mA
I Mini: 20mA Courant mini de veille : <3mA environ
D R = externe Last (muss angeschlossen = externe Last (muss angeschlossen werden.)

werden)
Max. Spitzenstrom: 5A (elektrisch geschützt)
I Max Dauerstrom: 500mA I Leckstrom (aus): <3mA
I Max Dauerstrom: 500mA
I Min: 20mA
I Leckstrom (aus): <3mA
S R = extern last (måste finnas ansluten) = extern last
Max. stötström: 5A (elecktroniskt avsäkrad)

I Max kont.ström: 500mA I Frånslaget läge :<3mA
Min ström: 20mA I Max kont.ström: 500mA
I Läckström : <3mA
E R = carga externa debe estar conectada = Carga externa
Corriente max de entrada : 5A (protegida eléctricamente)

I max continua 500mA I carga no conectada (3mA)
I Min: 20mA I Max continua : 500mA
I carga no conectada : <3mA
R = Uitwendige belasting
NL (dient bedraad te worden) = Uitwendige belasting
Max. inloopstroom : 5A (electronisch beveiligd)

I Max. continue stroom : 500mA I Zonder belasting :<3mA
I Min: 20mA Max. continue stroom : 500Ma
I Zonder belasting :<3mA
R = zewnętrzne obciążenie (musi być = zewnętrzne obciążenie

PL
podłączone)
Max. prąd rozruchowy: 5A (elektrycznie zabezpieczony)

Max. prąd ciągły: Prąd wyłączenia <3mA
Prąd min.: 20mA Max. prąd ciągły: 500mA
Prąd wyłączenia: <3mA
Page 13
Function and
GB High level DRY = ON Low level WET = ON
LED indication Niveau haut Sec = Passant Niveau bas
TROCKEN = EIN Mouillé = Passant
Oberer Begrenzer NASS = EIN
Indication de
F Hög nivå TORR = TILL Unterer Begrenzer
fonctionnement Nivel alto SECO=ON Låg nivå VÅT = TILL
Hoog niveau Nivel bajo HUMEDO=ON
Funktion und DROOG = AAN Laag niveau NAT = AAN
D Wysoki poziom DRY = ON Niski poziom WET = ON
LED-Anzeige
Funktion och Short circuit Internal

S
LED-indikering load fault
or I max >
500mA
Indicacion de
E
funcionamiento
Court circuit, Défaut
pas de interne
Functie en charge en
NL
led-aanduiding série
ou I max >
500mA
Funkcjonalność i
PL
wskaźnik LED
Kurzschluss Interner
oder Fehler
PLC (positive input) ∆U
I max >
∆U <100µA <100µA
Automate (entrée positive) 500mA
<3V IL IL <3V IL IL
Positiver Eingang für SPS
3 2 1 3 2 1 2 3 1 2 3 1
Positiv PLC-utgång
PLC para entrada positiva Kortslutning Internt fel
PLC voor positieve input + I/P + I/P + I/P + I/P eller
Podłączenie do PCL PLC PLC PLC PLC I max >
500mA
∆U <100µA ∆U <100µA
PNP dc Carga en Fallo
Sortie PNP <3V IL IL <3V IL IL
cortocircuito interno
PNP Ausgang 3 2 1 3 2 1 3 2 1 3 2 1 I max >
PNP-utgång 500mA
Salida PNP
PNP uitgang
Wyjście PNP Kort-sluit- Inwendige
+V 0V +V 0V +V 0V +V 0V
belasting of I fout
max.>
500mA
<3mA <3mA
Load switching ac/dc ∆U ∆U
Commutation de la charge ca/cc <12V <12V
Lastschalter AC/DC Chwilowe Wewnętrz
3 1 3 1 2 1 2 1
Last brytare ac/dc włączenie w ne
Commutación carga ca/cc obwodzie uszkodzen
ac/dc belastings-verandering lub max. ie
Bezpośrednie obciążenie 0V +V 0V +V 0V +V 0V +V prąd >
ac/dc N L1 N L1 N L1 N L1 500mA
L.E.D
On 1Hz On 1Hz ¼Hz 3Hz
= Load on. = Load off.

= Relais excité = Relé au reposo
= Last ein. = Last aus.
= Belastning till. = Belastning från.
= Carga on. = Carga off.
= Belasting aan. = Belasting uit.
= Pod napięciem. = Bez napięcia.
Page 14
Fixing screw
Wiring
GB
Use only connector supplied
Seal
Joint
Dichtung
Cablage Tätning
F max
Utiliser le connecteur fourni Junta
1.5mm2 Dichting
(AWG 16)
Podkładka
Anschluss
D
Bitte nur den mitgeliefertern Plug Assembly
Anschlussstecker verwenden
Elektrisk anslutning
S
Använd endast medföljande
kabelkontakt
Ø max 8mm
Conexionado (0.31 in)
E
Usar únicamente el conector Ø min 6mm
suministrado (0.24 in)
Bedrading
NL Maak enkel gebruik van de
geleverde connector Insert cable into plug housing
Insérer le câble dans le connecteur
Przewody elektryczne Kabel in Steckergehäuse einführen
Należy tylko używać złacza Stick kabeln genom kabelkontaktens hus
PL Insertar el cable en el conector
dostarczonego wraz z
De kabel in de plugbehuizing inbrengen
przyrządem
Przewody należy doprowadzić do
urządzenia wykorzystując Plug Fitted
poszczególne elementy dławika wg.
Relay connection warning:
GB Vibrating Fork requires a minimum current of 3mA, which continues to flow when Vibrating Fork is ‘off’. If
selecting a relay to wire in series with Vibrating Fork, the user must ensure that the drop-out voltage of
the relay is greater than the voltage which will be generated across the relay coil when 3mA flows
through it.
Précaution pour le raccordement aux relais:
F Le Vibrating Fork consomme en permanence un courant de 3mA. Si l’on choisit de raccorder un relais
en série avec le Vibrating Fork, l’utilisateur doit s’assurer que le courant de maintien du relais soit
supérieure au courant de veille (3mA env) du détecteur sinon il restera collé en position "Travail".
Bei Relaisanschluss beachten:
D Vibrating Fork benötigt einen minimalen Leckstrom von 3mA, auch im “AUS”-Zustand. Mit einem Relais
in Reihe muss sicher gestellt sein, dass die Abfallspannung des Relais größer als der Spannungsabfall
über die Relaisspule ist, wenn 3mA fließen.
Observera vid reläanslutning:
S Vibrating Fork kräver en lägsta ström av 3mA för att fungera, även då den slagit från. Det betyder att
reläets frånslagsspänning måste vara större än den spänning som genereras över reläspolen då en
läckström på 3mA flyter genom den.
Precauciones para la conexión a los relés :
E El Vibrating Fork consume permanentemente una corriente de 3mA. Si se quiere conectar un relé en
serie con el Vibrating Fork, el usuario debe asegurarse de que la caida de tensión a nivel del relé sea
superior a la tensión generada a través de la bobina del relé cuando ésta consuma 3mA
Voorzorgmaatregelen voor het aansluiten aan een relais :
NL De Vibrating Fork verbruikt permanent 3mA. Wanneer men een relais in serie aansluit met de Vibrating
Fork, dient de verbruiker zich ervan te verzekeren dat het stroomverlies ter hoogte van het relais hoger
is dat de onstane stroom doorheen de spoel van het relais, wanneer deze 3mA verbruikt.
Uwaga: Podłączenie przekaźników
PL Vibrating Fork wymaga minimalnego prądu zasilania (3mA) gdy stan wyjść urządzenia jest nieaktywny.
W przypadku wykorzystania dodatkowych przekaźników, sterowanych Vibrating Forkiem, urzytkownik
musi być pewny, że napięcie zwolnienia przekaźnika jest większe niż napięcie generowane w
przekaźniku kiedy przepływa przez niego prąd podtrzymania w wysokości 3mA w stanie nieaktywnego
Vibrating Forka.
Page 15
No magnet Normal condition
Sans aimant Magnetic test point GB
Ohne magnet
Ingen magnet
Geen magneet
Sin imán Point test magnetique F
Bez magnesu
Magnetische Funktionsprüfung D
Magnetisk testpunkT
S
With magnet
Avec aimant Test condition Punto test magnético
E
Met Magneet
Mit magnet
Imantado
Med magnet NL
Con magneto
Magnetischtestpunt
Z magnesem
Magnetyczny punkt testujący PL
Cover orientation GB
Orientation du connecteur F
Steckerausrichtung D
Kontaktdon orientering S
Orientación del conector E
Orientatie van de plug NL
Orientacja dławika kablowego PL
The Vibrating Fork is IP66 and IP67 when El Vibrating Fork es IP66 y IP67 cuando se
GB correctly assembled with the supplied E instala con el cable apropiado y el conector
connector and suitable cable. que se proporciona
Le Vibrating Fork est IP66 et IP67 De Vibrating Fork is IP66 en IP67 indien hij
F lorsqu’équipé du connecteur fourni et du NL wordt aangesloten met de bijgeleverde
câble approprié. connector en een geschikte kabel.
Bei Anschluss mit dem mitgelieferten Vibrating Fork posiada stopień ochrony
D Anschlussteil und einem geeigneten Kabel ist PL IP66 oraz IP67. Dla zachowania tej cechy
der Vibrating Fork IP66 und IP67. należy zwrócić uwagę na prawidłowe
podłączenie kabli z wykorzystaniem
dostarczonego łącza i usytuowania dławika.
Vibrating Fork är IP66 och IP67 när det
S medföljande kontaktdonet och en lämplig
kabel har monterats korrekt
Page 16
Temperature Technical data GB
Limites de température
Temperatur
Tillåten F
Donnees techniques
arbetstemperatur
Temperatura
Temperatuur Technische Daten
D
Tekniska data S
Datos Técnicos E
Technische gegevens NL
Pressure
Limites de pression Dane techniczne PL
Druck
Tryck
Presión
Druk
Ciśnienie
Density p 0,6 - 1,6 Viscosity v max. 10000 cPs

Densité r 0,6 - 1,6 Viscosité v max. 10000 cPs
Dichte p 0,6 - 1,6 g/cm Viskosität v max. 10000 cP
3
Densitet ρ 0,6 - 1,6 kg/dm Viskositet v max. 10000 cP
Densidad 0,6 – 1,6 Viscosidad v max. 10000 cPs
Densiteit 0,6 - 1,6 Viscositeit v max. 10000 cPs
Gęstość 0,6 - 1,6 Lepkość maksymalna. 10000 cPs
Tamb = Ambient temperature Tamb = Température ambiante

GB Tp = Process temperature F Tp = Température du liquide
p = Process pressure p = Pression dans le réservoir
Tamb = Umgebungstemperatur Tamb = Omgivningstemperatur

D Tp = Prozesstemperatur S Tp = Vätsketemperatur
p = Prozessdruck p = Processtryck
Tamb = Omgevingstemperatuur Tamb = Temperatura ambiente

NL Tp = Procestemperatuur E Tp = Temperatura del líquido
p = Procesdruk p = Presión en el tanque
Tamb = Temperatura otoczenia

PL Tp = Temperatura procesu
p = Ciśnienie procesowe
Page 17
Cable gland supplied
Presse-étoupe fourni Technical data GB
Kabelverschraubung
Kontaktdon med kabel-
förskruvning Donnees techniques F
Geleverde kabelwartel
Prensaestopas
Dławik dostarczony z Technische Daten D
Ø38 urządzeniem
Notch to indicate fork
orientation
Repère d’orientation Tekniska data S
de la fourche
Nut für Sensor-
orientierung
Spår för indikering av Datos Técnicos E
gaffelläge
Borne de Tierra externo

Externer Erdanschluss
Dodatkowe uziemienie
Borne externe de terre
Muesca para indicar
Uitwendige aarding
orientación de la Technische gegevens NL
horquiilla External earth
Een inkeping duidt de
M4 x 4.5mm
Extern jord
Vibrating Fork
orientatie van de vork Dane techniczne PL

aan
Rowek określający
położenie widełek
41 A/F
41 sur plats A
SW 41
B
Thread 1” or ¾”
Filetage 1” ou ¾” 13 mm
Gewinde 1” oder ¾”
Gänga1” eller ¾”
Rosca 1” o ¾” Nominal sensing level (vertically mounted)
Schroefdraad 1” of ¾” Point de détection (montage vertical)
Gwint 1” lub ¾” Nennschaltpunkt (vertikale Montage)
Nominell omkopplingspunkt (vertikal montering)
Nivel de detección(montaje vertical)
Nominaal schakelpunt (vertikaal gemonteerd)
Nominalny poziom czułości (montaż pionowy)
Vibrating
fork
A mm 116
B mm 98
C mm 239
Page 18
K7741
Accessories & spare Material: Non-asbestos BS7531 grade X Seal

GB
parts carbon fibre with rubber binder Joint
Dichtung
Accessoires & Matière: Sans amiante BS7531 grade X Fibre
F Tätning
pieces de rechange de carbone avec liant en caoutchouc
Junta
Zubehör und Material: Kohlefaser mit Gummibindung, Dichting
D
Ersatzteile asbestfrei Uszczelnienie
Tillbehör och Material: Asbestfri kolfiber (BS7531 Grade X)

S
reservdelar med bindemedel I gummi
Accesorios & Material: Sin amianto BS7531 grado X fibra de

E
recambios carbono con junta de goma
Bijbehorigheden en Materiaal: Asbestvrij BS7531 grade X

NL
onderdelen koolstofvezels met rubber bindmiddel
Akcesoria i części
PL Materiał: włókno węglowe w osłonie gumowej
zapasowe
SK267
Material: 316 SS fitting. Fluorocarbon Hygienic adaptor boss

(FPM/FKM) ‘O’ ring
Raccord alimentaire
Matière: Acier inox 316 avec joint torique en Hygiene Einschweißfitting
Fluorocarbon (FPM/FKM) Hygienisk adapter
Adaptador higiénico
Material: 316 rostfr. Stahl, Fluorocarbon Hygiënische aansluitmof
(FPM/FKM) ‘O’ Ring
Przyłącze higieniczne
Material: Syrafast stål Fluorocarbon

(FPM/FKM) ‘O’ ring
Material: Accesorio en acero inox. AISI 316,

Junta tórica en Fluorocarbon (FPM/FKM)
Materiaal: Roestvrij staal 316 O-ring dichting

uit Fluorocarbon (FPM/FKM)
Materiał: 316 SS – króciec, Fluorocarbon
(FPM/FKM) – O-ring
51mm (2”) Tri-clover kit SK266

Kit comprises:- Material: 316 St. steel, Fluorocarbon
Vessel fitting, clamp ring, seal (FPM/FKM) seal
Un kit comprend:- Matière: Acier inox 316, joint en
Raccord à souder, bague de serrage, joint Fluorocarbon (FPM/FKM)
Kit umfaßt:- Material: 316 rostfr. Stahl,
Behälterfitting, Klemmring, dichtung Fluorocarbon (FPM/FKM) Dichtung
Satsen omfattar:- Material: Syrafast stål 316
Tankanslutning klämhylsa, tätning Fluorocarbon (FPM/FKM)tätning
Cada kit comprende:- Fijación para depósito Material: Acero inox. AISI 316
junta clamp Junta Fluorocarbon (FPM/FKM)
Een kit bevat: Reservoiraansluiting, Drukrig Materiaal: Roestvrij staal 316
Dichting uit Fluorocarbon
Komplet obejmuje:- Materiał: stal nierdzewna 316
Króćce zbiornikowe, obejma, uszczelnienie Uszczelka - Fluorocarbon
Page 19
GB Specification
Application & mounting

Vibrating Fork will work in most liquids, including coating and aerated liquids and
slurries.
For use in safe area only. Mount in any position in tank or pipe. Mounting is by ¾”
or 1” thread or hygienic fitting.
Construction
Wetside material 316L Stainless steel (1.4404)
Gasket (1” BSPP model only) Non-asbestos
BS7531 Grade X carbon fibre
with rubber binder
Dryside materials
Body 304 Stainless steel with polyester label
LED window Flame retardent Polyamide
(Pa12) UL94 V2
Plug Polyamide glass re-inforced
Plug seal Nitrile butadiene rubber
Ingress protection
rating IP66 an IP67
Operating conditions
o o
Wetside temp. -40 C to +150 C
o o
Ambient temp. -40 C to +80 C
(derated to 50oC at 150oC wetside)
Wetside pressure -0.25 bar g to +100 bar g at 50oC
(30 bar for hygienic fittings)
Liquid sg 0.6 to 2.0
Liquid viscosity 0.2 to 10,000 cPs
Switching point 13mm from tip (vertical) / from edge
(water) horizontal) of fork
Hysteresis (water) +/- 1mm nom.
Switching delay 1 sec dry to wet / wet to dry.
Maximum altitude 2000m
Maximum humidity 100% RH
Electrical
Switching mode User selectable (Dry = on or Wet = on) by
selection wiring in plug
Protection Reverse polarity protected. Missing load /
short circuit protection.
Cable connection Via 4 way plug provided – DIN43650
Orientation – 4 position (90/180/270/360 deg.)
2
Max. conductor size 1.5mm
PG9 Cable gland provided for cable dia. 6mm to 8mm
Earthing Vibrating Fork must always be earthed
either through cable plug or using
external earth connection provided.
Safety EMC
E.M.C. Directive EN50081-1 (Emmissions)
EN50082-2 (Immunity) EN61326
L.V. Directive EN61010-1
Pollution degree 2, Category II (264V max)
Pollution degree 2, Category III (150V max)
Page 20
Specification F
Applications et montage
Vibrating Fork détectera la plupart des liquides, colles, vernis, peintures
même s'ils sont aérés ou chargés.
Utilisation hors zone dangereuse (non agréé ATEX SI ou ADF). Montage dans
n'importe quelle position sur cuve ou sur canalisation. Raccord fileté ¾” ou 1” male
Construction
Coté liquide Acier inox 316 C12
Joint (Modèle 1” BSPP seulement) Sans amiante
BS7531 Grade X fibre carbone/caoutchouc.
Boîtier Acier inox 304 avec etiquette en
polyester
Indicateur visuel Polyamide (Pa12) UL94 V2
résistant aux flammes
Connecteur Polyamide renforcé au verre
Joint connecteur Caoutchouc nitrile butadiène
Etanchéité IP66 et IP67
Conditions de service
o o
Température liquide. -40 C à +150 C
o o
Température ambiante -40 C à +80 C
(50oC pour 150oC liquide)
Pression -0.25 bar eff à +100 bar eff à 50oC
Densité relative 0.6 à 2.0
Viscosité 0.2 à 10,000 cps
Point de détection 13mm du bout (montage vertical) ou du bord
(montage horizontal) de la fourche pour de l’eau
Hystérésis (eau) +/- 1mm en moyenne.
Temps de réponse 1 seconde.
Maximum altitude 2000m

Maximum humidity 100% RH
Caractéristiques électriques
Commutation (Sonde sèche = passant ou bloqué) choisie par le
câblage du connecteur
Protection Contre inversion de polarité, court-circuit,
ou manque de charge dans la boucle 2 fils.
Raccordement Par connecteur 4 pôles – DIN43650
o
Orientable en 4 sens (90/180/270/360 .)
2
Capacité conducteur 1.5mm max.
Presse-étoupe (fourni) PG9 pour câble Ø 6mm à 8mm.
Mise à la terre Obligatoire soit par le connecteur, soit
par la borne sur la partie 6 pans
Agréments CE
Directive C.E.M. EN50081-1 (Emission)
EN50082-2 (Immunité) EN61326
Directive L.V. D EN61010-1
Pollution degré 2, Catégorie II,
(264V max)
Pollution degré 2, Catégorie III, (150V max)
Page 21
Technische
D
Daten
Applikation & Montage

Der Vibrating Fork arbeitet bei den meisten Flüssigkeiten, einschließlich klebrigen
und sprudelnden Flüssigkeiten sowie Schlämmen. Montage in beliebiger Lage an
Behältern und Rohrleitungen im Ex-freien Bereich mit 3/4” oder 1” Gewinde (siehe
Typenschlüssel)
Konstruktiver Aufbau
Benetzte Seite Rostfreier Stahl 316 (Werkst. Nr. 1.4404)
Dichtung (nur G1A) Asbestfrei, Kohlefaser mit Gummibindung
Trockene Seite
Gehäuse Rostfr. Stahl 304 mit Polyester Typenschild
LED-Fenster Flammenhemmendes Polyamid
(Pa12) UL94 V2
Stecker Polyamid, Glasfaserverstärkt
Steckerdichtung Nitril Butadien Gummi
Schutzart IP66 und IP67
Betriebsbedingungen
o o
Temp. nasse Seite -40 C bis +150 C
Umgebungstemp. -40 C bis +80 C (50oC bei 150oC nasse Seite)
o o
Druckbereich -0,25 bar bis +100 bar bei 50oC

Dichte 0,6 bis 2,0 g/cm³
Viskositätsbereich 0,2 bis 10.000 cP
Schaltpunkt (Wasser) 13 mm von Spitze (vertikal)/von Kante
Hysterese (Wasser) ±1 mm nom.
Schaltverzögerung 1 sec trocken zu nass/nass zu trocken
Max. Höhe ü.d.

Meeresspiegel 2000 m
Max. Luftfeuchtigkeit 100% RH
Elektrische Spezifikation
Funktionswahl Wählbar vor Ort (Trocken = Ein oder
Nass = Ein) durch Steckeranschluss
Geräteschutz Verpolungsschutz sowie Schutz bei
fehlender Last als Kurzschlussschutz
Kabelanschluss über mitgelieferten 4-poligen Stecker-
DIN 43650, Orientierung vier Positionen
(90°/180°/270°/360°)
2
Max. Leiterquerschnitt 1,5 mm
PG9 Kabelverschraubung für Kabeldurchmesser 6 mm bis 8 mm.
Erdung Vibrating Fork muss immer geerdet werden,
entweder über den Steckeranschluss,
oder die externe Erdschraube.
Sicherheit und EMV

E.M.V. Vorschrift EN50081-1 (Emmission)
EN50082-2 (Immunität) EN61326
Niederspannungsrichtlinie EN61010-1
Verschmutzungsgrad 2, Isolierstoffgruppe II
(264V max) und Isolierstoffgruppe III (150V max)
Page 22
Teknisk S
Specifikation
Applikation och installation

Vibrating Fork arbetart I kan användas till både tunnflytande och trögflytande vätskor
samt slam. Den påverkas ej av skum eller luftbubblor. Valfritt monteringsläge i
tankens tak, vägg, botten eller i rörledning. ¾” eller 1” utvändig gänganslutning.
Konstruktion
Våtsida Syrafast stål 316
Tätning (Endast 1” BSPP) Asbestfri kolfiber
(BS7531 Grade X) med bindemedel av gummi
Torrsida Hus: Rostfritt stål 304 med etikett i polyester
LED-fönster: Flamtåligt Polyamid
(Pa12) UL94 V2
Kontaktdon Glasfiberförstärkt polyamid
Kontakttätning Nitrilgummi
Kapslingsklass IP66 och IP67
Driftsdata
o o
Vätsketemp. -40 C till +150 C
o o
Omgivn.temp. -40 C till +80 C (dock max 50°C vid 150° på
våtsidan)
Vätsketryck -0.25 bar till +100 bar övertryck vid 50oC
Vätskedensitet 0.6 till 2.0 kg/dm3
Vätskeviskositet 0.2 till 10,000 cP
Omslagspunkt 13 mm från gaffelns spets vid vertikalt montage (vatten)
3 mm över gaffelns centrumlinje vid horisontellt
montage
Hysteres (vatten) ± 1mm nominellt
Fördröjning 1 sekund våt till torr eller torr till våt
Max. höjd ö.h. 2000m

Max. rel. fuktighet 100% RH
Elektriska data
Kontaktfunktion Väljs i kabelkontakten (torr=till eller våt=till)
Belastningen ansluts i serie
Max brytström 500 mA kontinuerligt
Max stötström 5 A elektroniskt skyddad
Min brytström 20 mA kontinuerligt
Strömförbrukning <3,0 mA kontinuerligt (i frånläge)
Spänningsfall Ca 6,5 V vid 24 VDC/5,0 V vid 240 VAC
Anslutningssp. 24 till 240 V (± 10%) AC eller DC
Skyddad mot omvänd polaritet, frånvaro av belastning och kortslutning.
Anslutning via 4-vägs avskiljbart kontaktdon (ingår) - DIN 43650.
PG9 kabelförskruvning ingår. Kabeldiameter 6-8 mm.
2
Max area per ledare: 1,5 mm
Orientering 4 lägen (90/180/270/360°)
Vibrating Fork skall alltid jordas antingen via kontaktdonet eller vaktens externa
jordanslutning
Tillämpliga EU-direktiv
EMC-direktivet EN50081-1 (Emission)/
EN50082-2 (Immunitet) EN61326
Lågspänningsdirektivet EN61010-1
Miljöklass 2 kategori II (264V max)
Miljöklass 2 kategori III (150 V max)
Page 23
E Características
Montaje y aplicación
El Vibrating Fork funcionará con la mayoria de líquidos, colas, barnices, pinturas,
liquidos con burbujas y residuales.
Para emplear solamente fuera de zonas peligrosas. Se puede montar en cualquier
posición en depósitos y tuberías.
Montaje mediante rosca macho de ¾” o 1” ó accesorio higiénico.
Materiales
Partes húmedas Acero inox. AISI 316
Junta (sólo en el modelo de 1” BSPP) Sin amianto
BS7531 Grado X fibra al carbono con goma
Cuerpo
Acero inox. AISI 304 con etiqueta de poliéster
Ventana para LED Polyamide (Pa12) UL94 V2
retardante a la llama
Tuerca Nylon reforzado con fibra de vidrio
Junta tuerca Goma butadienonitrilo
Grado de protección IP 66/67 s/ EN60529
Condiciones de funcionamiento
o o
Temp. Partes húmedas. -40 C a +150 C
Temp. Ambiente. -40 C a +80 C (-50oC a 150oC partes
o o
húmedas)
Presión partes húmedas -0.25 bar a +100 bar a 50oC
(30 bar para accesorios higiénicos)
Densidad líquidos 0.6 a 2.0
Viscosidad líquidos 0.2 a 10,000 cps
Punto de conmutación 13mm desde el extremo (vertical) /
desde el borde (horizontal) de la
horquilla.
Histéresis (agua) +/- 1mm nom.
Altitud máxima 2000m

Humedad máxima 100% HR
Caracteristicas electricas
Retardo conmutación 1 segundo de seco a húmedo/ húmedo a seco.
Eléctrico
Modo de conmutación Seleccionable por el usuario (Seco=on ó
Húmedo=on) mediante selector en
conector
Protección Protegido contra reversión de polaridad
y contra cortocircuitos.
Conexión cables Mediante conector 4 vías – DIN43650
Orientación – 4 posiciones 90/180/270/
360 grados.)
2
Tamaño máx. cables 1.5mm
Se suministra con prensa estopas PG 9 apto para cables de 6 a 8 mm.
Puesta a tierra Vibrating Fork debe conectarse siempre
a tierra, ya sea mediante el conector
o empleando la conexión externa a tierra
que incorpora.
Seguridad CEE
Directiva CEE EN50081-1 (Emisiones)
EN50082-2 (Inmunidad) EN61326
Directiva Baja EN61010-1
Tension Grado 2, Categoría II (264V máx.)
Grado 2, Categoría III (150V máx.)
Page 24
Specificaties NL
Toepassing & montage

Vibrating Fork zal werken in de meeste vloeistoffen, met inbegrip van aanklevende,
beluchte en beladen vloeistoffen, ook van slib. Alleen bestemd voor toepassing in niet
explosiegevaarlijke omgevingen. Montage in om het even welke positie in tanks en
leidingen. Montage via een 3/4” of 1” schroefdraad of een een hygiënische
aansluiting.
Constructie
Vloeistofzijde Roestvrij staal 316
Dichting (1” BSPP model alleen) Asbestvrij)
BS7531 Grade X koolstofvezels met
rubber bindmiddel
Droge zijde
Behuizing Roestvrij staal 304 met polyester label
LED venster Zelfdovend Polyamide
(Pa12) UL94 V2
Plug Glasvezelversterkt polyamide
Plugdichting Nitril Butadïeenrubber
Protectiegraad IP66/67 volgens EN60529
Werkingsvoorwaarden
o
Vloeistof T bereik -40oC tot +150oC
Omgevings To -40oC tot +80oC (beperkt tot 50oC bij een
vloeistoftemperatuur van 150oC)
Vloeistofzijde -0,25 bar g tot +100 bar g bij 50oC
drukbereik (30 bar voor hygiënische aansluiting)
Vloeistofdensiteit : 0,6 tot 2,0
Vloeistofviscositeit : 0,2 tot 10,000 cps
Schakelpunt 13mm vanaf het uiteinde (vertikale montage)
/ as van de vorkbladen (horizontale montage)
Hysteresis (water) +/- 1mm nominaal
Responsietijd 1 sec. droog naar nat / nat naar droog
Maximum hoogte 2000m

Maximale vochtigheid 100% Relatieve Vochtigheid
Electrische karakteristieken
Schakelfunctie Selecteerbaar door de gebruiker (Droog = Aan
/of Nat = Aan) door bedraden in de plug
Protectie Beschermd door polariteitsinversie,
afwezigheid van belasting / kortsluiting
Kabelaansluiting Via een 4-wegsplug – DIN43650
Orientatie – 4 posities (90/180/270/360 gr.)
2
Max geleiderssectie 1,5mm
Kabelwartel Pg9 kabelwartel - kabels van diam. 6 tot 8mm
Aarding Vibrating Fork dient steeds geaard te worden
via de kabel of een voorziene aardingsaansluiting.
EMC Directieven
E.M.C. Directieve EN50081-1 (Emissies)
EN50082-2 (Immuniteit) EN61326
L.V. Directieve Richtlijn EN61010-1 (lage voltage)

Niveau van de verontreiniging 2, Categorie II (264V
maximum).
Niveau van de verontreiniging 2, Categorie III (150V
maximum).
Page 25
PL Specyfikacja
Zastosowanie i montaż.
Vibrating Fork przeznaczony jest dla większości cieczy, łącznie z cieczami
napowietrzanymi i z tędęcją do tworzenia powłok oraz dla zawiesin.
Przeznaczony dla stref niezagrożonych wybuchem. Vibrating Fork może być
montowany w każdej pozycji w zbiorniku lub na rurociągu z wykorzystaniem przyłączy
gwintowych lub higenicznych
Konstrukcja
Materiał części zwilżanych
Stal nierdzewna 316L (1.4404)
Podkładka Włókna węglowe pokryte gumą, bez azbestu
(dla modelu 1” BSPP) - BS7531 Grade X carbon fibre
Materiał elementów suchych
Obudowa Stal nierdzewna 304
Okno diody LED Żywica poliamidowa
(Pa12) UL94 V2
Łącze Szkło poliamidowe
Uszczelnienie łącza Kauczuk polibutadienowy
Stopień ochrony IP66 - IP67
Warunki pracy
o o
Temperatura procesu. -40 C to +150 C
o o
Temperatura otoczenia. -40 C to +80 C
(50oC dla tem. procesu 150oC)
Ciśnienie procesowe -0.25 bar g do +100 bar g przy 50oC
(30 bar dla przyłączy higenicznych)
Gęstość cieczy 0.6 to 2.0
Lepkość cieczy 0.2 to 10,000 cps
Punkt przełączenia 13mm od końca widełek (dla montażu pionowego)
(woda) 13mm od najniższego punktu widełek (dla montażu
poziomego)
Histereza (dla wody) +/- 1mm nom.
Opóźnienie przełączenia 1s przy zanurzeniu i wynurzeniu
Max. wysokość pracy 2000m
Max. wilgotność 100% RH
Własności elektryczne
Tryb przełączania Wybierany przez użytkownika (Dry = on lub Wet = on) za
pomocą odpowiedniej konfiguracji podłączenia
przewodów elek.
Ochrona Zabezpieczenie przed odwrotną polaryzacja, przed
zwarciem, brakiem obciążenia.
Przyłącza kabli Łącze wg. DIN43650
Orientacja – 4 pozycje (90/180/270/360 stopni.)
2
Max. rozmiar przewodów 1.5mm
Dławik kablowy PG9 Średnica kabla - 6mm do 8mm.
Uziemienie Vibrating Fork musi być zawsze uziemiony poprzez
zaciski lub specjalne przyłącze zewnętrzne
Bezpieczeństwo EMC
Dyrektywy E.M.C. EN50081-1 (Emisja)
EN50082-2 (Odporność) EN61326
Dyrektywy L.V. EN61010-1
Stopień zanieczyszczenia 2, Kategoria II (264V max)
Stopień zanieczyszczenia 2, Kategoria III (150V max)
Page 26
GB Maintenance
F Maintenance
D Wartung
S Underhåll
E Mantenimiento
NL Onderhoud
PL Konserwacja
Check connector and seals are correctly fitted, also that the connector fixing screw and gland are
GB Inspection tight. Check unit for damage and if damaged do not use.
Contrôler la mise en place du connecteur et des joints et le serrage de ces derniers. Si le matériel
F Contrôle est endommagé, ne pas mettre en service.
Bitte prüfen, dass der Anschlussstecker richtig eingesteckt ist, die Dichtungen richtig sitzen und
D Inspektion dass die Schraube des Anschlusssteckers und die Verschraubung fest angezogen sind. Bitte
untersuchen, ob das Gerät beschädigt ist. Bei Beschädigung nicht anschliessen.
Kontrollera att kabelkontakt och tätningar är korrekt monterade samt att skruv och kabeltätning är
S Inspektion åtdragna. Kontrollera att delarna är oskadade. Skadade delar kasseras.
Comprobar que el conector y los cierres estan montados correctamente y si el material está
E Inspección dañado, no ponerlo en servicio.
Kijk na of de connector en dichtingen correct zijn geplaatst, alsook dat de connector-

NL Inspectie bevestigingsschroef en rondsel goed zijn aangedrukt.
Kontroleer het toestel op beschadiging en gebruik het niet indien beschadigd
Należy sprawdzić złącze i dławik. Prawidłowość montażu i szczelność połączenia. Przeprowadzić

PL Kontrola należy oględziny urządzenia, jeśli są ślady uszkodzenia nie należy podłączać zasilania i
niezwłocznie zgłosić problem do producenta.
Page 27
Installation & Instruction Leaflet
IP2044/GEA
Vibrating Fork December 2006

R01 - 4420 0024 001 PDF

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IOM Manual

Customer: Keppel Fels Ltd., Singapur

Project: Keppel Fels – B354 / B355 / B356 / B357 / B360 / B361

engineering for a better world GEA Mechanical Equipment

01 15.04.2014 As built 2321Ce 2152Hu

00 04.12.2013 Issued for information 2321Ce 2152Hu

GEA Mechanical Equipment

GEA Westfalia Separator

Designation: Safety precautions

engineering for a better world GEA Mechanical Equipment

GEA Mechanical Equipment

GEA Westfalia Separator Group

For your safety

• Observe the accident prevention regulations!

• Follow the instructions in the manual.

GEA Westfalia Separator Group

1.1 Safety markings ....................................................................................... 5

GEA Westfalia Separator Group

1.1 Safety markings

1.1.1 Safety markings and their meaning

Be sure to adhere to the plant

Disconnect power prior to start-

Before carrying out work on the

GEA Westfalia Separator Group

Frequency converter operation!

Warning of extreme surface

The surfaces of the plant components

Danger due to electrical current!

Before working on electrical com-

• Lock the installation to prevent it from being accidentally switched on.

GEA Westfalia Separator Group

Potential equalisation (protec-

GEA Westfalia Separator Group

1.2 Performing work on a plant

The plant works reliably, provided that

Special attention must be given to:

1.2.1 Demands on the operating and maintenance personnel

Westfalia Separator accepts no liability for damage caused by unqualified

The operator of the plant

GEA Westfalia Separator Group

Westfalia Separator offers a an extensive range of training and advanced train-

1.2.2 Spare part requirements

• Use only genuine spare parts from Westfalia

1.2.3 Electrical installation

• Electrical work may only be car-

• Carry out voltage equalization.

GEA Westfalia Separator Group

1.2.4 Before start-up

• Check that the lubrication and cool-

• Check whether the supervisory

• Check that the product lines are set

GEA Westfalia Separator Group

• Wear ear protection.

In case of frequency converter

• Do not feed product which is catego-

GEA Westfalia Separator Group

• The plant may be fed with inflam-

• When processing products harmful

Only in case of hot operation:

GEA Westfalia Separator Group

1.2.6 Shut-down and »Emergency-Off«

• For shut-down refer to the chapter

GEA Westfalia Separator Group