GEA Westfalia Separator Technical Document

TECHNICAL DOCUMENTATION
TECHNISCHE DOKUMENTATION
Westfalia Separator® Energy Compact Unit
EDITION / AUSGABE - 05.11.2010
CUSTOMER / KUNDE: Wärtsilä Finland Oy
PROJECT / PROJEKT: Naryanganj, Bangladesh
WS-Order No. / WS-Bestell No.: 452.911.795
MODEL / MODELL: Lube Oil Treatment
GEA Mechanical Equipment / GEA Westfalia Separator Group GmbH

2 Naryanganj, Bangladesh / 452.911.795 / Lube Oil Treatment / 05.11.2010
The authors are always grateful for comments and suggestions for improving the
documentation. They can be sent to:
Die Verfasser freuen sich immer über Kommentare und Ratschläge diese
Dokumentation betreffend. Sie können gesandt werden an
© GEA Westfalia Separator
GEA Mechanical Equipment

GEA Westfalia Separator Group GmbH
Werner-Habig-Str. 1, 59302 Oelde
Phone +49 2522 77-0 · Fax +49 2522 77-1778
ws.systems@geagroup.com · www.westfalia-separator.com

Naryanganj, Bangladesh / 452.911.795 / Lube Oil Treatment / 05.11.2010 3
CONTENTS / INHALT
COVER SHEET
DECKBLATT
1 Safety
Sicherheit
1.1 Safety Precautions
Sicherheitshinweise
1.2 Qualification Operators
Qualifikation des Personals
1.3 Safety Precautions and User Instructions for Machine and Plant Components
Sicherheits- und Benutzerhinweise für Maschinen- und Anlagenkomponenten
2 System Description
Systembeschreibung
2.1 Installation Guidelines
Installationsrichtlinien
3 Documents Relating to Orders
Projektbezogene Dokumente
3.1 Set of Final Drawings
Zeichnungssatz
Operating Data Sheet
Prozess Datenblatt
Installation Diagram P&ID
Installationsschema
Graphical Symbols
Grafiksymbole
Device List
Geräteliste
Dimensioned Drawing
Aufstellungsplan
Circuit Diagram
Stromlaufplan
3.2 Order Sheet
Bestellung
4 Control Unit
Steuer- und Regeleinrichtung
4.1 Control Unit
E-40
4.2 Adjustment values and fault signals
Einstellwerte u. Betriebstörungen
5 Separator
Separator
5.1 OSE Separator – Instruction Manual
OSE Separator – Betriebsanleitung

OSE 40-0196-067
Parts Catalogue
Ersatzteilkatalog
Parts Catalogue
Ersatzteilkatalog
Parts Catalogue
Ersatzteilkatalog
Parts Catalogue
Ersatzteilkatalog
Parts Catalogue
Ersatzteilkatalog
Parts Catalogue
Ersatzteilkatalog
5.2 Induction Motor
Drehstrommotor
6 Pumps
Pumpen
6.1 Gear Pump
Zahnradpumpe
Type KF 63
6.2 Diaphragm Pump Unit
Membranpumpeneinheit
Type P1
7 Filters
Filter
7.1 Y-Strainer
Schmutzfänger
Type 22.050
7.2 Air Cleaner
Nassluftfilter
8 Heat Exchanger
Wärmetauscher
8.1 Plate Heat Exchanger
Plattenwärmetauscher
Type OC4
9 Valves, Fittings and Assembly
Ventile, Armaturen und Zubehör
9.1 Valves
Ventile
Ball Valve, 2-way
2-Wege Kugelhahn
Ball Valve
Kugelhahn
Type DKA
Type NKB
Straight Through Control Valve
Durchgangs-Stellventil
Type 440

Actuator, Electric-type
Antrieb, elektrisch
Safety Valve
Sicherheitsventil
Type 961
Solenoid Valve
Magnetventil
Type GMV 3197
Type 330
Type 331
Non Return Valve
Rückschlagventil
Type MR
Type RK 41
Gate Valve
Muffenschieber
Pressure relief valve
Druckbegrenzungsventil
Type SPVF
9.2 Other Parts
Sonstige Teile
Steam Trap
Kondensatableiter
Type FT-14
Air compressor regulator
Wartungseinheit
Type C06-K10
10 Measurement
Messtechnik
Important!
Wichtig!
10.1 Pressure Measurement
Druck-Messtechnik
Pressure Gauge
Druckmessgerät
Type 213.40
Pressure Transmitter
Drucktransmitter
10.2 Level Switch
Füllstandgrenzschalter
Type Liquitec
10.3 Water detector
Wasserdetektor
Type SK1-HT125
11 Additional Components & Accessories
Zusätzliche Komponenten & Zubehör
11.1 CIP Unit
CIP Einheit
Set of Final Drawings

Zeichnungssatz
Installationsschema
Graphical Symbols
Grafiksymbole
Device List
Geräteliste
Dimensioned Drawing
Aufstellungsplan
Wartungseinheit
Type C06-K10
Diaphragm Pump Unit
Type P200

1 Safety
Sicherheit
1.1 Safety Precautions

Sicherheitshinweise
1.2 Qualification Operators
Qualifikation des Personals
1.3 Safety Precautions and User Instructions for Machine and Plant Components
Sicherheits- und Benutzerhinweise für Maschinen- und Anlagenkomponenten

Safety precautions
for plants
No.: 9001
Edition: 0310
Designation: Safety precautions
GEA Mechanical Equipment / GEA Westfalia Separator

2 9001 / 0310 / Safety precautions / 09.03.2010
Subject to modification!
documentation. They can be sent to

GEA Westfalia Separator GmbH
Phone +49 2522 77-0 · Fax +49 2522 77-1778

9001 / 0310 / Safety precautions / 09.03.2010 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
documentation.
• 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 con-
verter, 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 accor-
dance with our operating instructions.
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
(176 oF).
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

Phone +49 2522 77-0 · Fax +49 2522 77-1778
Qualification of staff
Ausgabe: 0310
Bezeichnung: Qualification of staff

2 0310 / Qualification of staff / 10.03.2010
documentation. They can be sent to

Phone +49 2522 77-0 · Fax +49 2522 77-1778

0310 / Qualification of staff / 10.03.2010 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
separator / 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 informa-

tion.
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.

4 0310 / Qualification of staff / 10.03.2010
– 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 Mineraloil Systems
GmbH.

0310 / Qualification of staff / 10.03.2010 5
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note

Phone +49 2522 77-0 · Fax +49 2522 77-1778
Westfalia Separator
Mechanical Separation
Mineraloil Systems GmbH
Division
Safety Precautions and
User Instructions
for
Machine and Plant Components
No.: 2058-9601-100
Edition: 0707
Westfalia Separator
2 Mineraloil Systems GmbH
The authors are always grateful for comments and suggestions for improving
the documentation. They can be sent to
Westfalia Separator
Werner-Habig-Str. 1
D-59302 Oelde
© Westfalia Separator
2058-9601-100 / 0707
Westfalia Separator
Mineraloil Systems GmbH 3
1 General 5
1.1 Qualification of the personnel ..................................................................5

1.2 Structure of documentation...................................................................... 5
2 Safety precautions 6
2.1 Correct usage ..........................................................................................6

2.2 Incorrect usage ........................................................................................ 6
2.3 Representation of warnings ..................................................................... 7
2.4 Remaining risks .......................................................................................8
2.5 Designation..............................................................................................8
2.6 Safety precautions for the operating staff................................................9
2.7 Safety precautions for adjustment / commissioning ................................ 9
2.8 Safety precautions for maintenance ........................................................9
2.9 Safety precautions for specific types of risks........................................... 9
2.9.1 Electricity..................................................................................................9
2.9.2 Oils, fats, and chemicals.......................................................................... 9
3 Product overview 10
3.1 Description and operating principle .......................................................10

3.2 Operating conditions..............................................................................10
3.3 Transport................................................................................................10
3.4 Storage ..................................................................................................10
4 Installation 11
4.1 Measures to be taken prior to installation..............................................11

4.2 Mounting ................................................................................................11
4.2.1 Fitting with threaded connection............................................................11
4.2.2 Fitting with flange connection ................................................................11
4.3 Electrical connection.............................................................................. 12
4.4 Pneumatic connection ...........................................................................12
4.5 Operation in an explosion-hazarded area ............................................. 12
5 Maintenance and servicing 13
5.1 Cleaning and servicing ..........................................................................13

5.2 Maintenance ..........................................................................................13
5.3 Repair ....................................................................................................13
6 Disposal 14
7 Spare parts 14
2058-9601-100 / 0707
Westfalia Separator
2058-9601-100 / 0707
Westfalia Separator
1 General
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 (maintenance, servicing, repair) and
– disposal
For questions that cannot be solved with the aid of this documentation, please
check back with Westfalia Separator Mineraloil Systems GmbH.
Using this manual and direct handling of the component require specific qualifi-
cation of staff.
1.1 Qualification of the personnel

As mentioned under these instructions, certain operations may only be carried
out by qualified staff. For identifying the qualification level Westfalia Separator
Mineraloil Systems GmbH uses the following standard terms:
• 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 Structure of documentation

By default the documentation for components comprises:
1. Instruction manuals for separators and/or start-up and shut-down instruc-

tions for plants
2. Safety precautions and user instructions (this document)
3. Reference to the component instructions and/or the technical data sheet of
the component according to DIN paper 146, in accordance with DIN EN
62079
2058-9601-100 / 0707
Westfalia Separator
Danger through non-observance of the documentation

• All documents mentioned have to be adhered to!
– Instruction manuals for separators and/or start-up and shut-down instruc-
WARNING! tions for plants
– Safety precautions and user instructions
– 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 any time.
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 use or thirds or the component or other valuables might
get impaired if it is
– operated by untrained or uninstructed staff,
– incorrectly used,
– inadequately maintained or serviced.
2.1 Correct usage

The component is incorporated in machines and plants.
Precise details on the function of the components 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 any time.
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 systematically not allowed. The only
exception: this is confirmed in the order or is mentioned in the Instruction Man-
ual or in the manufacturer’s data sheet.
2.2 Incorrect usage

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 one.
Non compliant 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
2058-9601-100 / 0707
Westfalia Separator
Solely the user is responsible for the operation and/or layout of the component.
Incorrect usage of components

Danger to life and limb and/or risk of material damage when disregarding me-
chanical, chemical and electric danger.
DANGER! • The specific characteristics stated in the documents supplied with the com-
ponents have to be observed and adhered to.
2.3 Representation of warnings

Depending on likelihood and nature of a risk, warnings are set up with a signal
keyword (exclamation) and in a signal colour according to ANSI Z535:
Warning of a direct threat of danger, leading to serious injury or even death.
DANGER!
Warning of a possibly dangerous situation that might lead to serious injury or

even death.
WARNING!
Warning of a possibly dangerous situation that might lead to minor injury. This
text can also be used when warning of material damage.
CAUTION!
This symbol is to inform for better understanding the component and its func-
tions and tasks.
• A bullet point us 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.
Be sure to adhere to stickers, symbols and warning signs directly fastened on
the component. Do NOT remove them, and keep them clearly readable!
2058-9601-100 / 0707
Westfalia Separator
2.4 Remaining risks

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.
Hazardous voltage - danger to life

Risk of death or serious injury through electric shock!
• Work on electric apparatus and/or on live component equipment must be
DANGER! performed by qualified staff only.
• Disconnect the power supply to electric equipment if required.
• Secure against unexpected restarting.
• Apply a warning sign forbidding to switch 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 working on components with surface temperatures above 50 °C or be-
low 0 °C, wear temperature-isolating safety gloves.
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.
2.5 Designation
The following signs and plates are fastened on the component or its accesso-
ries:
Warning of dangerous voltage!
The sign is fastened on the electric terminal box.

The terminal box may only be opened by qualified staff.
Nameplate The nameplate contains specific component data.
2058-9601-100 / 0707
Westfalia Separator
2.6 Safety precautions for the operating staff

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.
Only this is how errors can be avoided – 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.
2.7 Safety precautions for adjustment / 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.
2.8 Safety precautions for maintenance

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.
2.9 Safety precautions for specific types of risks
2.9.1 Electricity
Never carry out work on live parts!
Do nor change safety-affecting 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.
2.9.2 Oils, fats, and chemicals

When handling oils, fats, and chemicals, adhere to applicable rules and regula-
tions and manufacturers’ data sheets for these materials concerning storage,
handling, usage, and disposal!
After eye or skin contact, rinse the affected area immediately with water.
2058-9601-100 / 0707
Westfalia Separator
3 Product overview
3.1 Description and operating principle

The detailed description and functional principle of the relevant component are
given in the respective 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 will only be used where the layout crite-
ria comply with the values stated on the nameplate. Correct transport and ap-
propriate 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
Be sure to comply with the following :
• 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.
2058-9601-100 / 0707
Westfalia Separator
4 Installation
Component-specific information is given in the component manual!

Prior to installation, read and adhere to the safety precautions given in chapter 2
of this manual. Observe the accident prevention regulations!
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.
Take the following measures prior to installation:

• 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.
After installation
• Check for possible leakage and for proper function.
• Arrange for 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.
2058-9601-100 / 0707
Westfalia Separator
4.3 Electrical connection

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

Risk of death or serious injury through electric shock!
• Work on electric apparatus and/or on live component equipment must be per-
DANGER! formed by qualified staff only.
• Disconnect the power supply to electric equipment.
• Prevent unexpected restarting.
• Apply a warning sign forbidding to switch 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

Use conditioned compressed air only. Install a upstream compressed-air control
assembly if required.
4.5 Operation in an explosion-hazarded area

Any use in an explosion-hazarded area is systematically not allowed. The only
exception: this is confirmed in the order or is mentioned in the Manual or in the
manufacturer’s data sheet.
2058-9601-100 / 0707
Westfalia Separator
5 Maintenance and servicing
This chapter comprises: cleaning and servicing, maintenance and repair.

Prior to repair work, read and observe chapter 2 of this manual.
5.1 Cleaning and servicing
Damage to the component, caused by a layer of dirt

Plugging-up of functional openings. Impaired of heat dissipation!
• Arrange for efficient covering of the component when carrying out dirt-emitting
CAUTION! work near the separator or the plant (e.g. laying concrete, brickwork, painting,
sand-blasting).
• Clean at regular intervals.
Malfunction due to damage to the component

Risk of material damage through inappropriate cleaning!
• When cleaning with aqueous detergents, mind the type of enclosure 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 with strong mechanical
pressure.
• Use lint-free cleaning rags only.
5.2 Maintenance
The maintenance intervals have to be re-determined (shortened) by the opera-
tor according to prevailing operating conditions.
The component has to be checked and maintained for operating-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 component with tools (e.g. drilling).
2058-9601-100 / 0707
Westfalia Separator
6 Disposal
Be sure to comply with applicable legislation for adequate and environmentally-

friendly 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! • Be sure to decontaminate prior to disposal.
7 Spare parts
Use only genuine spare parts from Westfalia Separator.
2058-9601-100 / 0707
Westfalia Separator
2058-9601-100 / 0707
Westfalia Separator
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
2 System Description
Systembeschreibung
2.1 Installation Guidelines

Installationsrichtlinien

Installation Instructions
No.: 2058-9601-020
Edition: 0410
For: Separators
Mechanical Separation / GEA Westfalia Separator
GEA Westfalia Separator Mineraloil Systems GmbH reserves the right to modi-
fications without notice.
The authors will always be grateful for any comments on possible errors and
faults and for suggestions to improve this documentation. They can be sent to
GEA Westfalia Separator Mineraloil Systems GmbH
Werner-Habig-Str. 1
D-59302 Oelde
Copies of this documentation can be obtained from our local agencies.
2058-9601-020/ 0410
Mechanical Separation / GEA Westfalia Separator 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 car-

ried 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 in-

struction manuals of all units and fittings.
For your safety

 Strictly adhere to instructions marked with this symbol.
This avoids damage to the separator and other equipment.
 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 separator or plant com-
ponents and the processes.
 Use only genuine spare parts from Westfalia Separator.

– safety risks,
If a safety risk occurs, this may have legal consequences for the re-
sponsible persons. In such cases, Westfalia Separator accepts no li-
ability or warranty claims.
2058-9601-020 / 0410
1 General 6
1.1 Safety precautions ................................................................................... 7

1.2 Material .................................................................................................... 7
1.3 Installation ................................................................................................ 7
1.4 Storage .................................................................................................... 9
1.4.1 Installation of controls .............................................................................. 9
1.5 Transport................................................................................................ 11
1.5.1 Transporting the separator .................................................................... 13
1.6 Preservation measures on site .............................................................. 17
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 34
3.1 Water quality .......................................................................................... 35

3.2 Supply pressure and temperature ......................................................... 35
3.3 Water connection for operating, filling and displacement water ............ 36
3.4 Dimensions and number of consumers ................................................. 36
3.5 Water quantity ........................................................................................ 38
4 Compressed air 40
4.1 Compressed air quality .......................................................................... 41

4.2 Supply pressure ..................................................................................... 41
4.3 Compressed air consumption of the separators OSD, OSE and OTC.. 41
5 Product lines 43
5.1 General .................................................................................................. 44

5.2 Pipe cross-sections ................................................................................ 44
2058-9601-020/ 0410
5.3 Functional description ............................................................................ 44

5.4 Information on pressure monitoring ....................................................... 44
5.5 Piping ..................................................................................................... 46
5.6 Maximum suction head .......................................................................... 47
5.6.1 Pressure line .......................................................................................... 47
5.6.2 Pre-filter ................................................................................................. 48
5.7 Feed pump ............................................................................................. 48
5.8 Oil pre-heater ......................................................................................... 48
5.9 Installation examples ............................................................................. 49
5.9.1 Steam-heated plate heat exchanger with (PI controlled) control valve . 49
5.9.2 Steam-heated tubular heat exchanger with (PI controlled) control valve
............................................................................................................... 50
5.9.3 Thermal oil-heated plate heat exchanger with (PI controlled) control
valve....................................................................................................... 51
5.9.4 Thermal-oil-heated tubular heat exchanger with (PI controlled) control
valve....................................................................................................... 52
5.10 Securing plate heat exchangers ............................................................ 53
5.11 Safety valve ........................................................................................... 54
6 Solids tank 55
6.1 Recommended criteria for solids tank ................................................... 56

6.1.1 Tank vent ............................................................................................... 57
6.1.2 Set-up of the solids tank venting ........................................................... 58
6.2 Solids discharge lines ............................................................................ 59
6.2.1 Solids discharge lines with shut-off flap................................................. 60
6.2.2 Standard installation of shut-off flaps .................................................... 60
6.2.3 Installation recommendation for shut-off flaps ....................................... 62
6.3 Operating and dirty water discharge lines ............................................. 63
6.3.1 Separators of OSD and OSE ................................................................. 64
7 Electrical installation 65
7.1 Control cabinet ....................................................................................... 66

7.1.1 Electrical connection .............................................................................. 68
7.1.2 External voltages ................................................................................... 68
7.1.3 Shipboard operation .............................................................................. 69
7.1.4 Onshore operation ................................................................................. 69
7.2 Electro-magnetically compatible installation .......................................... 70
7.3 Valves .................................................................................................... 71
7.3.1 Solenoid valve block .............................................................................. 71
7.3.2 Terminal box .......................................................................................... 72
7.3.3 Separator with sensor bloc .................................................................... 73
7.4 Dual-purpose thermometer .................................................................... 74
7.5 Electrical installation of transmitters and electric motors ....................... 75
7.6 Electrical execution ................................................................................ 75
7.6.1 Earthing the separator ........................................................................... 76
7.6.2 Voltage equalisation of the separator .................................................... 76
7.6.3 Voltage equalization of the electric heater ............................................. 77
7.6.4 Voltage equalization of the foundation frame ........................................ 77
7.6.5 Voltage equalisation of the control cabinet ............................................ 78
7.7 Electric motors procured by the customer ............................................. 79
7.8 Installation and operation of control units .............................................. 80
2058-9601-020 / 0410
1 General
1.1 Safety precautions ................................................................................... 7

1.2 Material .................................................................................................... 7
1.3 Installation ................................................................................................ 7
1.4 Storage .................................................................................................... 9
1.4.1 Installation of controls .............................................................................. 9
1.5 Transport................................................................................................ 11
1.6 Preservation measures on site .............................................................. 17
2058-9601-020/ 0410
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.
2058-9601-020 / 0410
 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.
2058-9601-020/ 0410
1.4 Storage
 Parts may be stored only in original Westfalia Separator transport packaging.
 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.
2058-9601-020 / 0410
 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.
2058-9601-020/ 0410
1.5 Transport
The adjacent packing illustrates a

seaworthy packaging from Westfalia
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
2058-9601-020 / 0410
 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
2058-9601-020/ 0410
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 Fehler! Verweisquelle konnte nicht gefunden
werden.).
2058-9601-020 / 0410
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 mo-

tor to suspend the separator.
 Make sure the machine touches
down gently.
Fig. 9
2058-9601-020/ 0410
For OSD 35 and OSE 40 – separator with belt drive
 Screw two eye bolts 1 into the upper

section of the frame.
 Screw double nipple 2 into the hole
in the frame.
Fig. 10

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

down gently.
Fig. 11
2058-9601-020 / 0410
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
2058-9601-020/ 0410
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.
2058-9601-020 / 0410
2058-9601-020/ 0410
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
............................................................................................................... 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
2058-9601-020 / 0410
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
2058-9601-020/ 0410
Top view of separator
Fig. 16
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
2058-9601-020 / 0410
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
2058-9601-020/ 0410
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
2058-9601-020 / 0410
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
2058-9601-020/ 0410
2.5 Foundations
In order to avoid the influence of external vibrations,

 Foundations and foundation frames for Westfalia separators must not be rig-
idly connected 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
2058-9601-020 / 0410
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
2058-9601-020/ 0410
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.
2058-9601-020 / 0410
 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
 bolt tight with hexagon nuts 5.
 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
2058-9601-020/ 0410
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
2058-9601-020 / 0410
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 sections Fehler! Verweis-
quelle konnte nicht gefunden
werden. and 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
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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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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 Westfalia Separator or
– in accordance with the requirements of the classification societies.
 Use only genuine parts from 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 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 .......................................................................................... 35

3.2 Supply pressure and temperature ......................................................... 35
3.3 Water connection for operating, filling and displacement water ............ 36
3.4 Dimensions and number of consumers ................................................. 36
3.5 Water quantity ........................................................................................ 38
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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 m
3.2 Supply pressure and temperature
Fig. 30
2058-9601-020 / 0410
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
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
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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.
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
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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 con-
sumption
sumption
Separator Displace- Operating per cycle
Filling water per cycle
model ment water water without fill-
* ing water
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 =  (filling water + displacement water + operating water)
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2058-9601-020 / 0410
4 Compressed air
4.1 Compressed air quality .......................................................................... 41

4.2 Supply pressure ..................................................................................... 41
4.3 Compressed air consumption of the separators OSD, OSE and OTC.. 41
2058-9601-020/ 0410
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.
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2058-9601-020/ 0410
5 Product lines
5.1 General .................................................................................................. 44

5.2 Pipe cross-sections ................................................................................ 44
5.3 Functional description ............................................................................ 44
5.4 Information on pressure monitoring ....................................................... 44
5.5 Piping ..................................................................................................... 46
5.6 Maximum suction head .......................................................................... 47
5.6.1 Pressure line .......................................................................................... 47
5.6.2 Pre-filter ................................................................................................. 48
5.7 Feed pump ............................................................................................. 48
5.8 Oil pre-heater ......................................................................................... 48
5.9 Installation examples ............................................................................. 49
5.9.1 Steam-heated plate heat exchanger with (PI controlled) control valve . 49
5.9.2 Steam-heated tubular heat exchanger with (PI controlled) control valve
............................................................................................................... 50
valve....................................................................................................... 51
5.9.4 Thermal-oil-heated tubular heat exchanger with (PI controlled) control
valve....................................................................................................... 52
5.10 Securing plate heat exchangers ............................................................ 53
5.11 Safety valve ........................................................................................... 54
2058-9601-020 / 0410
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)
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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.
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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!
2058-9601-020/ 0410
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.
2058-9601-020 / 0410
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!
2058-9601-020/ 0410
 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
2058-9601-020 / 0410
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
2058-9601-020/ 0410
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
2058-9601-020 / 0410
5.9.4 Thermal-oil-heated tubular heat exchanger with (PI controlled)

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
2058-9601-020/ 0410
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 Westfalia Separator recommendation as example channel steel according
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./
Allen screw Lock Groove- Gasket Plate Hex head Hexagon
type
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)
2058-9601-020 / 0410
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
2058-9601-020/ 0410
6 Solids tank
6.1 Recommended criteria for solids tank ................................................... 56

6.1.1 Tank vent ............................................................................................... 57
6.1.2 Set-up of the solids tank venting ........................................................... 58
6.2 Solids discharge lines ............................................................................ 59
6.2.1 Solids discharge lines with shut-off flap................................................. 60
6.2.2 Standard installation of shut-off flaps .................................................... 60
6.2.3 Installation recommendation for shut-off flaps ....................................... 62
6.3 Operating and dirty water discharge lines ............................................. 63
6.3.1 Separators of OSD and OSE ................................................................. 64
2058-9601-020 / 0410
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
2058-9601-020/ 0410
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.
2058-9601-020 / 0410
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
2058-9601-020/ 0410
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
2058-9601-020 / 0410
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 Westfalia
Separator but can be ordered from Westfalia Separator.
 CP units or modules equipped with a sludge tank supplied by Westfalia Sepa-
rator 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 the C-generation
 Discharges I, II and III must be configured as illustrated in Fehler! Verweis-

quelle konnte nicht gefunden werden.).
 See section 6.1.1, table IV for tank vent connection.
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.
ATTENTION!
It must be ensured that the shut-off flaps are open during separator operation.
2058-9601-020/ 0410
2058-9601-020 / 0410
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
2058-9601-020/ 0410
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!
2058-9601-020 / 0410
6.3.1 Separators of OSD and OSE
 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
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 5 500
OTC 10 500
OTC 20 500
2058-9601-020/ 0410
7 Electrical installation
7.1 Control cabinet ....................................................................................... 66

7.1.1 Electrical connection .............................................................................. 68
7.1.2 External voltages ................................................................................... 68
7.1.3 Shipboard operation .............................................................................. 69
7.1.4 Onshore operation ................................................................................. 69
7.2 Electro-magnetically compatible installation .......................................... 70
7.3 Valves .................................................................................................... 71
7.3.2 Terminal box .......................................................................................... 72
7.3.3 Separator with sensor bloc .................................................................... 73
7.4 Dual-purpose thermometer .................................................................... 74
7.5 Electrical installation of transmitters and electric motors ....................... 75
7.6 Electrical execution ................................................................................ 75
7.6.1 Earthing the separator ........................................................................... 76
7.6.2 Voltage equalisation of the separator .................................................... 76
7.6.3 Voltage equalization of the electric heater ............................................. 77
7.6.4 Voltage equalization of the foundation frame ........................................ 77
7.6.5 Voltage equalisation of the control cabinet ............................................ 78
7.7 Electric motors procured by the customer ............................................. 79
7.8 Installation and operation of control units .............................................. 80
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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
14
13 2
9 5
12 8
11
10
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
2058-9601-020/ 0410
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
mm
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.
2058-9601-020 / 0410
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
2058-9601-020/ 0410
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.
2058-9601-020 / 0410
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.
2058-9601-020/ 0410
7.3 Valves
Only original valves from 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 Westfalia Separator which
is used in filling, displacement and op-
erating water lines.
Fig. 63
Connections
A Connecting terminal + 24 V DC
B Connecting terminal + 0 V DC
C Earth
D Status LED
Fig. 64
2058-9601-020 / 0410
7.3.2 Terminal box
All valves and monitoring instruments

are installed ready-to-connect on a lo-
cal 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 displacem.a.filling water
Fig. 65
2058-9601-020/ 0410
7.3.3 Separator with sensor bloc
Fig. 66
The components on the hood are wired to the terminal box.
2058-9601-020 / 0410
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.
2058-9601-020/ 0410
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 Westfalia Separator are

– the European standard EN 60 204 – Part 1 or
– VDE 0113 – Part 1
2058-9601-020 / 0410
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 mo-
tor 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.
Westfalia Separator selects:

2 2
10 mm < S < 25 mm Cu
Fig. 73
2058-9601-020/ 0410
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
2058-9601-020 / 0410
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
2058-9601-020/ 0410
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 Westfalia Separa-
tor.
2058-9601-020 / 0410
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.
2058-9601-020/ 0410
GEA Westfalia Separator Systems GmbH ● Werner-Habig-Straße 1 ● D-59302 Oelde (F.R. Germany)
Tel.: +49 (0) 25 22/77-0 ● Fax: +49 (0) 25 22/77-23 94 ●
2058-9601-020 / 0410
3 Documents Relating to Orders

Projektbezogene Dokumente
3.1 Set of Final Drawings

Zeichnungssatz
Operating Data Sheet
Prozess Datenblatt
Installationsschema
Graphical Symbols
Grafiksymbole
Device List
Geräteliste
Dimensioned Drawing
Aufstellungsplan
Circuit Diagram
Stromlaufplan
3.2 Order Sheet
Bestellung

Process Data Sheet
Nr. / No.: P402911795-9937-PDS002 Date 07.10.2010 Sheets:4 Sheet: 1
Module: Power Plants
Accompanying drawings: P402911795-9937-PID002

P402911795-9937-LAY002
Belongs to:
Drawn (Date/ Name): 07.10.2010 – A. Pohl Abt./ Dep.: 4220

Checked (Date/ Name): 07.10.2010 – J. Figge Abt./ Dep.: 4420
Standard checked (Date/ Name): 22.10.2010 – Ag. Abt./ Dep.: 4510
Customer: Wärtsilä Finland Oy
Project: Naryanganj, Bangladesh

Customers Order No.:
Order No.: 452.911.795
more project-order dates: Lube Oil Treatment
0 07.10.2010 First Issue A. Pohl J. Figge

Approval.
Rev. Date Status Date Details Prepared Approved Released

Werner-Habig-Straße 1, 59302 Oelde, Germany
Tel. +49 2522 77-0, Fax +49 2522 77-2488, www.westfalia-separator.com, www.geaquipment.com
Registered office: Oelde, Registered at the local court of Münster, HR B 7223, VAT-No. DE 812 459 899
Management: Markus Hüllmann (Chairman), Oliver Fidorra, Bernd Huber, Thomas Pelzer
Deutsche Bank AG, Bielefeld (BLZ 480 700 20) 066922600, SWIFT: DEUT DE 3 B, IBAN DE72 4807 0020 0066 9226 00
Commerzbank AG, Bielefeld (BLZ 480 800 20) 0213384200, SWIFT: DRES DE FF 480, IBAN DE13 4808 0020 0213 3842 00
Process Data Sheet
Process Conditions
Oil to be processed
Kind : LO
Viscosity : SAE40
Density : 0,912 kg/dm³ at 15°C
Feed temperature : min. 60°C
Separating temperature : 95°C
Separating capacity : 5000 dm³/h
Separator
Type : OSE 40-0196-067/25

Quantity : 1 per unit / 6 units
Operation mode : single stage, purifier / clarifier
Kind of ejection : total
Clean oil discharge press. : max. 2,0 bar g
Feed Pump
Kind : gear pump aggregate

Type : KF63 RF 2 – D 15
Quantity : 1 per unit, installed on the module
Pump capacity : 5280 l/h ( 88 l/min )
Suction height : - 0,4 bar g
Delivery height : 3 bar g
Steam Heater
Type: OC4-40
Quantity: 1 per unit, installed on the module
Steam Pressure (System) /: 7,0 bar (g) (8,0 bar abs)
Steam Temperature (System) /: ≈ 170 °C
Steam Pressure (Heater) /: 3 bar (g) (4 bar abs)
Steam Temperature (Heater) /: 142,9 °C
Steam Consumption /: ≈ 155 kg/h per heater /
Process Data Sheet
Environmental Conditions
Ambient temperature : +5°C up to +40°C

Humidity : up to 92% rel.
Altitude : up to 1000 m above sea level
Installation of equipment : indoor
Electrical Supply
Infeed : 3 x 415 V ± 5% / 50 Hz ± 2%
Control voltage : 230 V
Valve operating voltage : 24 VDC
Operating water (condensate is not permitted)
Hardness : max. 110 mg/dm³ CaCO3

Chloride ions : max. 100 mg/dm³
ph-value : 6,5 – 7,5
Suspensed matter : max. 50 mg/dm³
Particle size : max. 50 μm
Feed temperature : +10°C up to 85°C
Feed pressure : 3 - 10 bar g
Required capacity of the water feed system: 0,8 dm³/s (2880 dm³/h)
continuously available but only used during
bowl ejection cycle
Average water consumption per bowl ejection: ≈ 13 l per separator (approx. every 2 hours, sludge
dependend)
Compressed Air
Feed pressure : 3,0 – 10,0 bar g

Average air consumption : ≈ 115 Ndm³/h per separator (if one bowl ejection
happens every 2 hours)
Process Data Sheet
Adjustments and set points
T01 Temperature Controller TC 95°C
T01 Temperature alarm low TAL 80°C

Warning
T01 Temperature alarm high TAH 100°C

Warning
T01 Temperature alarm low TAL 75°C

Separation stop
T01 Temperature alarm high TAH 105°C

Separation stop
V27 Water pressure reducer PC 2 bar g, if operating

water valve is opened
V31 Compressed air control assembly PC 3,0 bar g
P12 Pressure transmitter clean oil discharge PAH 3,0 bar g pre-adjusted
P12 Pressure transmitter clean oil discharge PAL 1,0 bar g pre-adjusted
P61 Pressure transmitter sludge monitoring system PSH 0,5 bar g pre-adjusted
Customer: Wärtsilä Finland Oy, Proj. Project-/Order-No.: 911795 / 402911795
Naryanganj
Location: --- Project-title: 4220_63487_2
LO Separator Unit ECU OSE 40 with GEA Westfalia Separator
Steam Pre-Heater
---
Device list
Quotation-No.: 63487
Global Comments: ---
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Date: 22.10.2010 Dept.: 4220
Type: Power Plants Corr. Drawing: P402911795-9937-PID002A Belongs to: ---
Repl. for: --- Repl. by: --- Std. checked: --- ---
Explanations:
Priority (A): Procurement (B): Scope of Supply (C):
N = Obligatory M = Must be obtained from Westfalia L = Scope of supply by WS
E = Recommended K = May be obtained from Westfalia S = Supplied by client
P = Possible Z = Supplied by client F = To be removed
U = --- V = --- W = ---
Created Date: 29.06.2010 Checked Date: 22.10.2010 Approved Date: 22.10.2010 Document No.: Revison: Page:
By: 4220po By: 4420FIG By: 4510AG P402911795-9937-DVL002 1/6
Copyright. © All rights reserved Issued for: ,
Filename: sv010022\WS4220\Kundenaufträge\DM\Waertsilae Finland Oy\63487_Kom.402911795_Waertsilae, Proj. Naryanganj\4220_63487_2.prj@sv010022\WS Projekt/Dokumentablage\Basic and Process Engineering\Equipmentlisten\P402911795-9937-DVL002
Naryanganj
Steam Pre-Heater
---
Device list
Position Description Part-No. Type Object Material DN Rest Position Drive Remarks A B C
Gasket Material PN Feedback
Typ
B01 Strainer 0018-6128-210 22.050 EN-GJS-400-18LT DN50 N M L
(GGG-40.3) PN16
--- DIN
Flange
B02 Plate heat exchanger 9085-0002-033 OC4 - 40 1.4404 1“ N M L
---
SAE
Flange
B41 Demister 0018-8353-000 --- Steel 100 N M L
--- ---
Plug
male
B51 Strainer 0018-7338-210 22.050 EN-GJS-400-18LT DN20 N M L
(GGG-40.3) PN16
--- DIN
Flange
B52 Steam trap 0018-7589-200 FT14-10 EN-GJS-400-15 (GGG- 1’’ N M L
40) PN16
--- DIN 2999
Ins. Thr.
D01 Separator OSE 40-0196-067 --- incl. Electric Motor: 15 N M L
--- kW, 415 V, 50 Hz with
--- anti condensate heater
230 V, 50 Hz
D03 Gear pump unit 9990-0211-620 KF 63 RF 2 - D 15 EN-GJL-250 1 1/2’’ incl. Electric Motor: 2,2 N M L
FKM kW, 415 V, 50 Hz with
SAE anti condensate heater
Flange 230 V, 50 Hz
D41 Diaphragm pump 8078-9200-110 P1 Aluminium 1/2’’ NPT N M L
---
BSP Ins.
Thr.
Naryanganj
Steam Pre-Heater
---
Device list
Typ
K61 Water detector 0005-1464-060 SK1-HT125-FS-JM18-P-S-KL M30x1,5 Part of Separator N M L
--- ---
Outs.
Thr.
L43 Level Switch 0005-1475-010 Liquitec 1.4401 G1 N M L
--- ---
ISO Outs.
Thr.
L44 Level Switch 0005-1475-010 Liquitec 1.4401 G1 N M L
--- ---
ISO Outs.
Thr.
P11 Pressure gauge 0001-1572-600 213.40 / 0 bar ... 10 bar Brass 1/4’’ 0 to 10 bar, Part of N M L
--- --- Separator
DIN Outs.
Thr.
P12 Pressure transmitter 0005-1529-300 NAE 1.4301 1/4’’ 0 to 16 bar, 24V/DC, N M L

--- --- Part of Separator
Outs.
Thr.
P61 Pressure transmitter 0005-1529-300 NAE 1.4301 1/4’’ 0 to 16 bar, 24V/DC, N M L
--- --- Part of Separator
Outs.
Thr.
Q01 Pressure transmitter 0005-1533-300 NAE 1.4301 1/4’’ N M L
--- ---
DIN Outs.
Thr.
T01 Resistance thermometer 0001-1579-400 2xPT100 1.4571 1/2’’ integrated in V06 N M L
--- ---
DIN Outs.
Thr.
Naryanganj
Steam Pre-Heater
---
Device list
Typ
V01 Ball valve, 2-Way 2020-3093-050 DKA04-09OXU 1.4408 DN50 N M L
PN63
Welded
V04 Gate valve 0018-1408-650 IC201023 G-CuSn5ZnPb 1/2’’ N M L
--- PN10
BSP Ins.
Thr.
V05 Safety valve 0018-7445-400 67.961 / 0.6 MPa 1.4581 G 1/2’’ N M L
--- PN100
DIN ISO
228-1
Outs.
Thr./DIN
ISO 228-
1 Ins.
Thr.
V06 3/2-way piston valve 0018-7621-000 1.4301 DN25 N M L
FKM (Viton) PN16
DIN
Flange
V07 Ball Valve 0018-7958-630 NKB04 CuZn 1/4’’ --- N M L
PTFE PN64
DIN Outs.
Thr./DIN
Ins. Thr.
V08 Pressure relief valve 2020-3247-020 SPVF 25 B 2F 1A05 EN-GJL-250 (GG-25) DN25 N M L
--- PN16
SAE
3000 psi
Flange
V09 Non return valve 0018-6084-600 RK 41 CuZn35Ni DN25 --- N M L
--- PN16
DIN Int.
Flange
Naryanganj
Steam Pre-Heater
---
Device list
Typ
V11 Ball Valve 0018-7958-630 NKB04 CuZn 1/4’’ --- N M L
PTFE PN64
DIN Outs.
Thr./DIN
Ins. Thr.
V12 Non-return valve 0018-1346-300 MR330027 1.4301 G1 1/2’’ Part of Separator N M L
FKM PN16
DIN Ins.
Thr.
V13 Throttle valve with loose cone 0018-2992-650 --- G-CuSn5ZnPb 1 1/2’’ N M L
--- PN16
DIN Ins.
Thr.
V27 Solenoid valve block 0018-7614-000 --- Brass 3/4’’ 24 V/DC, Part of N M L
--- --- Separator
DIN Ins.
Thr.
V31 Air compressor regulator 0018-8303-560 C 06 - K 10 plastic material 1/4’’ N M L
NBR-Ms PN16
DIN Ins.
Thr.
V33 3/2-way solenoid valve 0018-7621-600 GMV 3197 Brass 1/8’’ NC integrated in V06 N M L
FKM ---
ISO Ins.
Thr.
V34 Throttle valve 0018-1677-280 491 Aluminium G1/4 N M L
---
DIN Ins.
Thr.
V35 3/2 way solenoid valve 0018-3734-620 0330 Brass 1/4’’ NC N M L
NBR ---
ISO Ins.
Thr.
Naryanganj
Steam Pre-Heater
---
Device list
Typ
V41 2-way ball valve 0018-1712-630 IK111623 Brass 1/2’’ N M L
PTFE PN25
DIN Ins.
Thr.
V51 Ball valve 0018-8365-000 VK 451004 Carbon steel DN25 N M L
PTFE PN16
DIN 2633
Flange
V52 Control valve 0018-8154-220 23.440 EN-JS1049 DN20 Kvs 2,5 N M L
PTFE-Chevron PN25
DIN 2633
Flange
V53 Ball valve 0018-8365-000 VK 451004 Carbon steel DN25 N M L
PTFE PN16
DIN 2633
Flange
V61 2/2 way solenoid valve 0018-8133-600 0331 Brass --- Part of Separator N M L
FKM
V62 2/2 way solenoid valve 0018-8133-600 0331 Brass --- Part of Separator N M L
FKM
0 1 2 3 4 5 6 7 8 9
BJN 011
.
BJN 061
600
560 8mm 250
25x80
1= K01
1A0 2= 3K2
SC
Filter
230Q1
230F3
230F4
3= 1K10
1F01
1U6
1-8
1U3
1U5
Filter 4= 1K11
control unit 5= 1K12
6= 1K13
40x80
3Q1
E40
40x80 7= 1K18
8= 1K19
0Q1
0F3
230T1 0T1
1S1 1S2 3S1 3S2 0H3 0H4

40x80
0 I 0 I
1S01 1X3 1X4 1X5 1X6

1000
960
PE
1K1
40x80
60x80
40x80
0R2
0Q2
0Q3
1A1
1A2
1U1
Q1
40x80
1T1
Q1
60x80
0M3
0X1 1X1 1X2 1X3
(Fan)
PE
Control cubicle
Steel plate thickness: 1,5mm
Cable glands
Door
Steel plate thickness: 2,0mm
11 x M 16
Protection class: "IP 54"
Colour: RAL 7035 5 x M 20
2 x M 40
3 x M 16 (spare)
1A0 Steuereinheit E40
control unit E40
0H3 Stillstandsheizung Separator Betrieb

space heater separator operation
0H4 Stillstandsheizung Zulaufpumpe Betrieb
space heater feed pump operation
M3 Schrankluefter
cabinet fan
Q1 Hauptschalter
main switch
REV. DATE MADE APPVD. MEMO NO. EXPLANATION
1S1 Separator Stop
C
C Wartsil„
separator stop Arrangement drawing
Power Plants
1S2 Separator Start
LO SEPARATOR SINGLE UNIT Westfalia Separator
separator start Systems GmbH
D-59302 Oelde
3S1 Zulaufpumpe Stop WITH OSE 40-0196
CORPORATION
feed pump stop
ACA UNITS
3S2 Zulaufpumpe Start
PRODUCT BJN 011-061 E 40
PROJ. NO.
ASLY. DRG
feed pump start
MADE 24.06.2010 BEE NARYANGANJ 4501386897
SCALE SIZE PAGE DRG.
CHKD.
NO. NO.
0
Gewicht: ca. 75kg 8106-2003-008
APPVD. KA 1 /5 REV.
weight: approx. 75kg
C
C COPYRIGHTED by GEA Westfalia Separator Systems GmbH, all rights reserved.
0 1 2 3 4 5 6 7 8 9
Steuereinheit E40
control unit E40
Bestell-Nr.
Westfalia Separator AG 0005-4050-710
order no.
Programm Nr.
8106-0E40-013
program no.
ACK
C
C Wartsil„
Arrangement drawing
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-008
APPVD. KA 2 /5 REV.
C
0 1 2 3 4 5 6 7 8 9
Reserve
spare
C
C Wartsil„
Arrangement drawing
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-008
APPVD. KA 3 /5 REV.
C
0 1 2 3 4 5 6 7 8 9
Klemmenkasten -1X10
terminal box -1X10
Drehzahlueberwachung
Vibro Spannungsversorgung
speed monitoring device
vibro power supply
2 x M 12
120 140 90
to operating water block
í 7mm
zum Steuerwasserblock
zum Sensorblock
to sensor block
2 x M 16
2 x M 16
140
93
1X10
2 x M 20
zum Steuerschrank
to control cabinet
Klemmenkasten 1X10 ist am Separator angebaut

terminal box 1X10 is mounted on the centrifuge
C
C Wartsil„
Arrangement drawing
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
Bestell-nr. 0005-1537-280 CHKD.
NO. NO.
0
order no. 0005-1537-280 8106-2003-008
APPVD. KA 4 /5 REV.
C
0 1 2 3 4 5 6 7 8 9
Sensorblock -1X20
sensor block -1X20
Pr fflansch
Handventil f r Pr fflansch Handventil f r Pr fflansch
Manometer (1)
manometer (1)
C
C Wartsil„
Arrangement drawing
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-008
APPVD. KA 5 /5 REV.
C
0 1 2 3 4 5 6 7 8 9
4x16mmý
E-Kabel getrennt
vom M-Kabel verlegen!
E-cables to be installed
separate from M-cable! Klemmenleistenbezeichnung
Schutzmaánahmen nach Bestimmungen des VDE terminal strip designation
cable type
cable type
bzw. zust„ndigen EVU ausf hren!
WS-Standard
Kabeltyp
Kabeltyp
All protective measures are to be taken in
accordance with electric codes, rules and
regulations! -Q1
terminal number
Klemmennummer
cable name
cable name
Kabelname
Kabelname
Anschluá
Anschluá
Br cken
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target
Ziel
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Z-Nr./Seite.Pfad
-1E0
Funktionstext
function text d-no./page.path
Einspeisung Betriebsspannung 1 -CUSTOMER L1 2 -Q1 5/1.1
10
incoming operation voltage


PE-Schiene PE -CUSTOMER PE PE-Bus -PE 5/1.2

PE-rail
C
C Wartsil„
Terminal connection diagram
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-108
APPVD. KA 1 /15 REV.
C
0 1 2 3 4 5 6 7 8 9
1.5mmý GN/YE
0.75mmý RD
0.75mmý RD/WH
3x1.5mmý
3x1.5mmý
E-Kabel getrennt
cable type
cable type
WS-Standard
WS-Standard
Kabeltyp
Kabeltyp
regulations! -1X0
terminal number
Klemmennummer
cable name
cable name
Kabelname
Kabelname
Anschluá
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Br cken
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Ziel
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Z-Nr./Seite.Pfad
-0M4
-0M3
Funktionstext
Steuerspannung 230VAC (Stillstandsheizung) 1 -0F3 2 X 5/2.1
10
control voltage 230VAC (space heater)
Steuerspannung 230VAC (Stillstandsheizung) 2 5/2.2

Steuerspannung 230VAC (Stillstandsheizung) 3 -0T1 vb X 5/2.2

Steuerspannung 230VAC (Stillstandsheizung) X -PE 4 5/2.2

Stillstandsheizung Separator 1 -R01 5 -1K1 22 X 5/6.3

space heater separator
Stillstandsheizung Separator 2 -R01 6 -1K1 51 X 5/6.3

space heater separator
PE-Schiene PE -R01 PE PE-Bus -PE 5/6.3

PE-rail
Stillstandsheizung Zulaufpumpe 1 -R02 7 -3Q1 22 X 5/7.4

space heater feed pump
Stillstandsheizung Zulaufpumpe 2 -R02 8 -3Q1 41 X 5/7.4

space heater feed pump
PE-Schiene PE -R02 PE PE-Bus -PE 5/7.4

PE-rail
C
C Wartsil„
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-108
C
0 1 2 3 4 5 6 7 8 9
16mmý BK
2.5mmý BK
4x2.5mmý
4x16mmý
E-Kabel getrennt
cable type
cable type
WS-Standard
WS-Standard
Kabeltyp
Kabeltyp
regulations! -1X1
terminal number
Klemmennummer
cable name
cable name
Kabelname
Kabelname
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Z-Nr./Seite.Pfad
-1E2
-1E1
Funktionstext
Separator 1 -D01 U1 1 -1T1 P2 X 5/6.1
10
separator
Separator 2 -D01 V1 2 -1K1 4 X 5/6.1

separator
Separator 3 -D01 W1 3 -1K1 2 X 5/6.1

separator
PE-Schiene PE -D01 PE PE-Bus -PE 5/6.2

PE-rail
Zulaufpumpe 1 -D03 U1 4 -3Q1 2T1 X 5/7.1

feed pump
Zulaufpumpe 2 -D03 V1 5 -3Q1 4T2 X 5/7.1

feed pump
Zulaufpumpe 3 -D03 W1 6 -3Q1 6T3 X 5/7.1

feed pump
PE-Schiene PE -D03 PE PE-Bus -PE 5/7.1

PE-rail
C
C Wartsil„
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-108
C
0 1 2 3 4 5 6 7 8 9
1.5mmý GN/YE
0.75mmý RD
0.75mmý RD/WH
4x1.5mmý
3x1.5mmý
3x1.5mmý
E-Kabel getrennt
cable type
cable type
WS-Standard
WS-Standard
WS-Standard
Kabeltyp
Kabeltyp
regulations! -1X2
terminal number
Klemmennummer
cable name
cable name
Kabelname
Kabelname
Anschluá
Anschluá
Br cken
target
target
Ziel
Ziel
Z-Nr./Seite.Pfad
-2M4
-2M2
-2M1
Funktionstext
Steuerspannung 230VAC 1 -230F3 2 X 5/2.6
10
control voltage 230VAC
Steuerspannung 230VAC 2 -1X2 5 X 5/2.7

Steuerspannung 230VAC 3 -230T1 vb X 5/2.7

Steuerspannung 230VAC X -PE 4 -1X2 11 X 5/2.7

Steuerspannung 230VAC 5 -1X2 2 X 5/5.5

Separator NotAus (Option) 1 -S01 21 6 -1X2 15 X 5/5.5

separator emergency stop (optional)
Separator NotAus (Option) 2 -S01 22 7 -1S01 21 X 5/5.5

separator emergency stop (optional)
PE-Schiene PE -S01 PE PE-Bus -PE 5/5.6

PE-rail
Steuerspannung 230VAC 8 -K01 A1 X 5/6.7

Schlammablauf Klappe (Option) 1 -S2 21 9 -3Q1 17 X 5/6.7

sludge discharge flap (optional)
Schlammablauf Klappe (Option) 2 -S2 22 10 -1F01 95 X 5/6.7

sludge discharge flap (optional)
PE-Schiene PE -S2 PE PE-Bus -PE 5/6.7

PE-rail
. 11 -1X2 4 X 5/8.1
Stellventil - Heizmedium 1 -V52 1 12 5/8.2

control valve - heating medium
Stellventil - Heizmedium 2 -V52 14 13 -1K18 14. X 5/8.2

Stellventil - Heizmedium 3 -V52 11 14 -1K19 14 X 5/8.2

PE-Schiene PE -V52 PE PE-Bus -PE 5/8.2

PE-rail
C
C Wartsil„
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-108
C
0 1 2 3 4 5 6 7 8 9
0.75mmý RD
E-Kabel getrennt
cable type
cable type
Kabeltyp
Kabeltyp
regulations! -1X2
terminal number
Klemmennummer
cable name
cable name
Kabelname
Kabelname
Anschluá
Anschluá
Br cken
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Ziel
Ziel
Funktionstext Z-Nr./Seite.Pfad
. 15 -1X2 6 X 5/8.3
10
C
C Wartsil„
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-108
C
0 1 2 3 4 5 6 7 8 9
0.75mmý BU_U
0.75mmý SC_KA
0.75mmý BU
7x1.5mmý
E-Kabel getrennt
cable type
cable type
WS-Standard
Kabeltyp
Kabeltyp
regulations! -1X3
terminal number
Klemmennummer
cable name
cable name
Kabelname
Kabelname
Anschluá
Anschluá
Br cken
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target
Ziel
Ziel
Z-Nr./Seite.Pfad
-3M1
Funktionstext
Drehzahlueberwachung 1 -1X10 1 1 -1U6 1+ X 5/11.4
10
Drehzahlueberwachung 2 -1X10 2 2 -1U6 2- X 5/11.5

Drehzahlueberwachung SC SC 5/11.5
PE-Schiene PE -1X10 PE-Bus PE-Bus -PE 5/11.5

PE-rail
Reinoel Ablaufdruck 3 -1X10 3 3 -1A1 X1_6 X 5/9.3

clean oil discharge pressure
Reinoel Ablaufdruck 4 -1X10 4 4 -1U1 L+ X 5/9.3

Schlammraumueberwachung 5 -1X3 7 X 5/9.4

sludge space monitoring
Schlammraumueberwachung 5 -1X10 6 6 -1A1 X1_9 X 5/9.4

Separator Betrieb X -1K1 63 7 -1X3 5 X 5/11.1

separator operation
Separator Betrieb X -1K1 64 8 -1A1 X2_2 X 5/11.1

separator operation
Separator Stoerung X -1F01 97 9 5/11.2

separator failure
Separator Stoerung X -1F01 98 10 -1A1 X2_3 X 5/11.2

separator failure
Reserve 11 5/11.3
spare
Reserve 12 -1A1 X2_4 X 5/11.3

spare
Reserve 13 5/11.6
spare
Reserve 14 -1A1 X2_6 X 5/11.6

spare
Wasserabfuhr 15 5/11.7
water monitoring system
C
C Wartsil„
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-108
C
0 1 2 3 4 5 6 7 8 9
0.75mmý BU
0.75mmý BRUE
0.75mmý BU/WH
4x1.5mmý
4x1.5mmý
7x1.5mmý
E-Kabel getrennt
cable type
cable type
WS-Standard
WS-Standard
WS-Standard
Kabeltyp
Kabeltyp
regulations! -1X3
terminal number
Klemmennummer
cable name
cable name
Kabelname
Kabelname
Anschluá
Anschluá
Br cken
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target
Ziel
Ziel
Z-Nr./Seite.Pfad
-3M9
-3M7
-3M1
Funktionstext
Wasserabfuhr 6 -1X10 7 16 -1A1 X2_7 X 5/11.7
10
Reserve 17 5/12.1
spare
Reserve 18 -1A1 X2_8 X 5/12.1

spare
PE-Schiene PE -L43 PE PE-Bus -PE 5/12.3

PE-rail
LSHH Schlammtank 3 -L43 3 19 -1X3 25 X 5/12.2

LSHH sludge tank
LSHH Schlammtank 2 -L43 2 20 -1A1 X2_9 X 5/12.2

LSHH sludge tank
LSHH Schlammtank 1 -L43 1 21 -1U1 L- X 5/12.2

LSHH sludge tank
Reserve 22 -1X3 28 X 5/12.3

spare
23
24
. 25 -1X3 19 X 5/13.1
LSH Schlammtank 1 -L44 2 26 -1X3 31 X 5/13.1

LSH sludge tank
LSH Schlammtank 2 -L44 3 27 -1A1 X2_16 X 5/13.1

LSH sludge tank
LSH Schlammtank 3 -L44 1 28 -1X3 22 X 5/13.1

LSH sludge tank
Reserve 29 -1X3 37 X 5/13.3

spare
PE-Schiene PE -L44 PE PE-Bus -PE 5/13.2

PE-rail
(Option) LSL Schlammtank 30 -1A1 X2_17 X 5/13.2

(optional) LSL sludge tank
C
C Wartsil„
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-108
C
0 1 2 3 4 5 6 7 8 9
0.75mmý BU_U
0.75mmý BU
0.75mmý BU/WH
7x1.5mmý
E-Kabel getrennt
cable type
cable type
WS-Standard
Kabeltyp
Kabeltyp
regulations! -1X3
terminal number
Klemmennummer
cable name
cable name
Kabelname
Kabelname
Anschluá
Anschluá
Br cken
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Ziel
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Z-Nr./Seite.Pfad
-4M2
Funktionstext
(Option) LSL Schlammtank 31 -1X3 26 X 5/13.2
10
(optional) LSL sludge tank
(Option) Separator Vibro Stufe 1 X -1X3 33 32 5/13.3

(optional) separator vibro stage 1
(Option) Separator Vibro Stufe 1 X -1X3 32 33 -1A1 X2_18 X 5/13.3

(Option) Separator Vibro Stufe 2 34 -1X5 7 X 5/13.4

(Option) Separator Vibro Stufe 2 1 -1X10 10 35 -1A1 X2_19 X 5/13.4

. 36 -1X3 39 X 5/13.5
. 37 -1X3 29 X 5/13.5
. 38 -1X4 2 X 5/13.5
Reserve 39 -1X3 36 X 5/14.1

spare
Reserve 40 -1A1 X1_22 X 5/14.1

spare
Reserve 41 5/14.2
spare
Reserve 42 -1A1 X1_23 X 5/14.2

spare
Reserve 43 5/14.3
spare
Reserve 44 -1A1 X1_24 X 5/14.3

spare
Reserve 45 5/14.4
spare
Reserve 46 -1A1 X1_25 X 5/14.4

spare
Reserve 47 5/14.5
spare
C
C Wartsil„
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-108
C
0 1 2 3 4 5 6 7 8 9
0.75mmý BU
E-Kabel getrennt
cable type
cable type
Kabeltyp
Kabeltyp
regulations! -1X3
terminal number
Klemmennummer
cable name
cable name
Kabelname
Kabelname
Anschluá
Anschluá
Br cken
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Ziel
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Funktionstext Z-Nr./Seite.Pfad
Reserve 48 -1A1 X1_26 X 5/14.5
10
spare
Reserve 49 5/14.6
spare
Reserve 50 -1A1 X1_27 X 5/14.6

spare
Reserve 51 -1A1 L+ X 5/14.7

spare
Reserve 52 -1A1 X1_28 X 5/14.7

spare
C
C Wartsil„
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-108
C
0 1 2 3 4 5 6 7 8 9
0.75mmý BU
0.75mmý BU/WH
0.75mmý RD
3x1.5mmý
7x1.5mmý
3x1.5mmý
E-Kabel getrennt
cable type
cable type
WS-Standard
WS-Standard
WS-Standard
Kabeltyp
Kabeltyp
regulations! -1X4
terminal number
Klemmennummer
cable name
cable name
Kabelname
Kabelname
Anschluá
Anschluá
Br cken
target
target
Ziel
Ziel
Z-Nr./Seite.Pfad
-4M6
-4M2
-4M1
Funktionstext
Separator Zulaufventil 1 -V33 + 1 -1A1 X2_22 X 5/15.1
10
separator feed valve
Separator Zulaufventil 2 -V33 - 2 -1X3 38 X 5/15.1

separator feed valve
PE-Schiene PE -V33 PE-Bus -PE 5/15.1

PE-rail
Fuell- und Verdraengungswasser 3 -1X10 15 3 -1A1 X12_2 X 5/15.2

fill- and displacement water
Steuerwasser Ventil 2 -1X10 12 4 -1A1 X12_3 X 5/15.3

operating water valve

PE-rail
Steuerwasser Ventil 5 5/15.3

Kreislaufventil 4 -1X10 16 6 -1A1 X12_5 X 5/15.5

circulation valve
Wasserabfuhrventil 6 -1X10 18 7 -1A1 X12_6 X 5/15.6

water discharge valve
Wasserabfuhrventil 5 -1X10 17 8 5/15.6

Ventil Schlammpumpe 1 -V35 + 9 -1A1 X2_34 X 5/17.3

valve sludge pump

PE-rail
Ventil Schlammpumpe 2 -V35 - 10 -1A2 5 X 5/17.3

valve sludge pump
C
C Wartsil„
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-108
C
0 1 2 3 4 5 6 7 8 9
0.75mmý BU
0.75mmý SC_KA
2x0.25mmý
4x1.5mmý
3x1.5mmý
E-Kabel getrennt
cable type
cable type
WS-Standard
Kabeltyp
Kabeltyp
regulations! -1X5
::
terminal number
Klemmennummer
cable name
cable name
Kabelname
Kabelname
Anschluá
Anschluá
Br cken
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target
Ziel
Ziel
Z-Nr./Seite.Pfad
-5M3
-5M2
-5M1
Funktionstext
TAH Separator Motortemperatur 1 -TAH 1 -1F01 T2 X 5/6.5
10
TAH separator motor temperature
TAH Separator Motortemperatur 2 -TAH 2 -1F01 T1 X 5/6.5

TAH separator motor temperature
PE-Schiene PE -TAH PE PE-Bus -PE 5/6.5

PE-rail
PI-Regelung 1 -T01 3 -1U5 3 X 5/9.5

PI-control
PI-Regelung 2 -T01 4 -1U5 4 X 5/9.6

PI-control
min/max-Temperaturueberwachung 3 -T01 5 -1A1 X1_14 X 5/9.7

min/max-temperature monitoring
min/max-Temperaturueberwachung 4 -T01 6 -1A1 X1_15 X 5/9.8

min/max-Temperaturueberwachung SC -5M2 SC SC SC 5/9.8

FI Durchflussmesser Zulauf BN -Q01 2 7 -1X3 34 X 5/18.1

FI flow meter feed
FI Durchflussmesser Zulauf BK -Q01 1 8 -1A2 2 X 5/18.1

FI flow meter feed
C
C Wartsil„
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-108
C
0 1 2 3 4 5 6 7 8 9
0.75mmý OG
7x1.5mmý
E-Kabel getrennt
cable type
cable type
WS-Standard
Kabeltyp
Kabeltyp
regulations! -1X6
terminal number
Klemmennummer
cable name
cable name
Kabelname
Kabelname
Anschluá
Anschluá
Br cken
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target
Ziel
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Z-Nr./Seite.Pfad
-6M1
Funktionstext
Sammelalarm 1 -CUSTOMER 1 -1K11 21 X 5/20.2
10
common alarm
Sammelalarm 2 -CUSTOMER 2 -1K11 24 X 5/20.2

common alarm
Separator Betrieb 3 -CUSTOMER 3 -1K1 44 X 5/20.3

separator operation
Separator Betrieb 4 -CUSTOMER 4 -1K1 43 X 5/20.3

separator operation
Zulaufpumpe Betrieb 5 -CUSTOMER 5 -3Q1 14 X 5/20.4

feed pump operation
Zulaufpumpe Betrieb 6 -CUSTOMER 6 -3Q1 13 X 5/20.4

feed pump operation
Zulaufpumpe Betrieb PE -CUSTOMER PE PE-Bus -PE 5/20.5

feed pump operation
Reserve 7 5/20.7
spare
Reserve 8 5/20.7
spare
C
C Wartsil„
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-108
C
0 1 2 3 4 5 6 7 8 9
3x0.75mmý
2x0.25mmý
5x1.5mmý
3x0.75mmý
7x1.5mmý
7x1.5mmý
E-Kabel getrennt
cable type
cable type
WS-Standard
WS-Standard
WS-Standard
WS-Standard
WS-Standard
Kabeltyp
Kabeltyp
regulations! -1X10
...
terminal number
Klemmennummer
cable name
cable name
Kabelname
Kabelname
Anschluá
Anschluá
Br cken
target
target
-10M5
-10M1
-10M6
Ziel
Ziel
Z-Nr./Seite.Pfad
-3M2
-4M2
-3M1
Funktionstext
PE-Schiene PE -V27B PE-Bus -1X4 PE-Bus PE 5/15.3
10
PE-rail
Reinoel Ablaufdruck PE -1X20 PE-Bus PE-Bus -PE 5/9.3

Drehzahlueberwachung X -SE + 1 -1X3 1 1 5/11.4

Drehzahlueberwachung X -SE - 2 -1X3 2 2 5/11.5

PE-Schiene PE-Bus -1X3 PE-Bus PE 5/11.5

PE-rail
Reinoel Ablaufdruck 1 -1X20 1 3 -1X3 3 3 5/9.3

Reinoel Ablaufdruck 2 -1X20 2 4 -1X3 4 4 5/9.3

Schlammraumueberwachung 5 5/9.4
Schlammraumueberwachung 3 -1X20 4 6 -1X3 6 5 5/9.4

Wasserabfuhr 4 -1X20 5 7 -1X3 16 6 5/11.7

(Option) Separator Vibro Stufe 2 8 5/13.4

(Option) Separator Vibro Stufe 2 9 5/13.5

(Option) Separator Vibro Stufe 2 10 -1X3 35 1 5/13.4

(Option) Separator Vibro Stufe 2 11 -1X10 17 5/13.4

Steuerwasser Ventil 1 -V27B + 12 -1X4 4 2 5/15.3

Steuerwasser Ventil 2 -V27B - 13 5/15.3

Fuell- und Verdraengungswasser 2 -V27A - 14 -1X10 11 5/15.2

C
C Wartsil„
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-108
C
0 1 2 3 4 5 6 7 8 9
4x1.5mmý
3x0.75mmý
7x1.5mmý
E-Kabel getrennt
cable type
cable type
WS-Standard
WS-Standard
WS-Standard
Kabeltyp
Kabeltyp
regulations! -1X10
terminal number
Klemmennummer
cable name
cable name
Kabelname
Kabelname
Anschluá
Anschluá
Br cken
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target
-10M5
Ziel
Ziel
Z-Nr./Seite.Pfad
-4M3
-4M2
Funktionstext
Fuell- und Verdraengungswasser 1 -V27A + 15 -1X4 3 3 5/15.2
10
Kreislaufventil 1 -1X20 8 16 -1X4 6 4 5/15.5

circulation valve
Wasserabfuhrventil 2 -1X20 10 17 -1X4 8 5 5/15.6

Wasserabfuhrventil 3 -1X20 11 18 -1X4 7 6 5/15.6


PE-rail
PE-Schiene PE -V27A PE-Bus -PE 5/15.2

PE-rail
C
C Wartsil„
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-108
C
0 1 2 3 4 5 6 7 8 9
3x1.5mmý
3x1.5mmý
3x0.75mmý
2x0.25mmý
2x0.25mmý
5x1.5mmý
4x1.5mmý
E-Kabel getrennt
cable type
cable type
WS-Standard
WS-Standard
WS-Standard
WS-Standard
Kabeltyp
Kabeltyp
regulations! -1X20
::
::
::
terminal number
Klemmennummer
cable name
cable name
Kabelname
Kabelname
Anschluá
Anschluá
Br cken
target
target
-20M5
-20M4
-20M3
-20M2
-20M1
Ziel
Ziel
Z-Nr./Seite.Pfad
-3M2
-4M3
Funktionstext
Reinoel Ablaufdruck BN -P12 2 1 -1X10 3 1 5/9.3
10
Reinoel Ablaufdruck BK -P12 1 2 -1X10 4 2 5/9.3

Schlammraumueberwachung BK -P61 1 3 5/9.4

Schlammraumueberwachung BN -P61 2 4 -1X10 6 3 5/9.4

Wasserabfuhr BK -K61 A/Q 5 -1X10 7 4 5/11.7

Wasserabfuhr BN -K61 + 6 5/11.7

Wasserabfuhr BU -K61 - 7 5/11.7

Kreislaufventil 1 -V62 + 8 -1X10 16 1 5/15.5

circulation valve
Kreislaufventil 2 -V62 - 9 5/15.5

circulation valve
Kreislaufventil PE -V62 PE-Bus -1X10 PE-Bus PE 5/15.5

circulation valve
Wasserabfuhrventil 2 -V61 - 10 -1X10 17 2 5/15.6

Wasserabfuhrventil 1 -V61 + 11 -1X10 18 3 5/15.6


PE-rail
Reinoel Ablaufdruck PE-Bus -1X10 PE-Bus PE 5/9.3

C
C Wartsil„
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-108
C
0 1 2 3 4 5 6 7 8 9
WSM_S_13_W1 14.09.06
(3/PE=3 incl.PE)
Kabelname Quelle Ziel gesamt verwendet Querschnitt Laenge * =

cable name source target total used cross-section length On site installation
Kabelbezeichnung von bis Kabeltyp Adern Adern mmý m Bemerkung ** =

Skid mounted cables
cable designation from up to cable type wires wires mmý remark
-0M3 -1X0 -R01 WS-Standard 3/PE 3/PE 1.5 - space heater separator
-0M4 -1X0 -R02 WS-Standard 3/PE 3/PE 1.5 - space heater feed pump
-1E0 -Q1 -CUSTOMER WS-Standard 4/PE 4/PE 16 - incoming 415V/50Hz
-1E1 -1X1 -D01 WS-Standard 4/PE 4/PE 16 - separator
-1E2 -1X1 -D03 WS-Standard 4/PE 4/PE 2.5 - feed pump motor
-2M1 -1X2 -S01 WS-Standard 3/PE 3/PE 1.5 - emergency stop external
-2M2 -1X2 -S2 WS-Standard 3/PE 3/PE 1.5 - sludge discharge flap (optional)
-2M4 -1X2 -V52 WS-Standard 4/PE 4/PE 1.5 - control valve - heating medium
-3M1 -1X3 -1X10 WS-Standard 7/PE 7/PE 1.5 - collective cable -1X10
-3M7 -1X3 -L43 WS-Standard 4/PE 4/PE 1.5 - LSHH sludge tank
-3M9 -1X3 -L44 WS-Standard 4/PE 4/PE 1.5 - LSH sludge tank
-4M1 -1X4 -V33 WS-Standard 3/PE 3/PE 1.5 - feed valve
-4M6 -1X4 -V35 WS-Standard 3/PE 3/PE 1.5 - valve pneumatic sludge pump
-5M1 -1X5 -TAH WS-Standard 3/PE 3/PE 1.5 - motor temperature separator
-5M2 -1X5 -T01 : 4+SC 4+SC 1.5 - double PT 100
-5M3 -1X5 -Q01 :: 2 2 0.25 - FI transmitter
-6M1 -1X6 -CUSTOMER WS-Standard 7/PE 7/PE 1.5 - collective cable to customer
-10M1 -1X10 -SE ... 2 2 0.25 - speed monitoring device
-10M5 -1X10 -V27A WS-Standard 3/PE 3/PE 0.75 - displacement a. filling water
-10M6 -1X10 -V27B WS-Standard 3/PE 3/PE 0.75 - operating water
-20M1 -1X20 -P12 :: 2 2 0.25 - PSL/H clean oil discharge
-20M2 -1X20 -P61 :: 2 2 0.25 - PSL sludge space monitoring
-20M3 -1X20 -K61 :: 3 3 0.75 - water monitoring system
-20M4 -1X20 -V62 WS-Standard 3/PE 3/PE 1.5 - circulation valve
C
C Wartsil„
List of cables
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-308
APPVD. KA 1 /2 REV.
C
0 1 2 3 4 5 6 7 8 9
WSM_S_13_W1 14.09.06
(3/PE=3 incl.PE)
Kabelname Quelle Ziel gesamt verwendet Querschnitt Laenge * =

cable name source target total used cross-section length On site installation
Kabelbezeichnung von bis Kabeltyp Adern Adern mmý m Bemerkung ** =

Skid mounted cables
cable designation from up to cable type wires wires mmý remark
-20M5 -1X20 -V61 WS-Standard 3/PE 3/PE 1.5 - water discharge valve
C
C Wartsil„
List of cables
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-308
APPVD. KA 2 /2 REV.
C
0 1 2 3 4 5 6 7 8 9
L1 /2.0
L2 /2.0
L3 /2.0
L1.1 /6.0
L2.1 /6.1
L3.1 /6.1
-Q1 1 3 5
12 14
44...63A
In:53A
Irm.:500A 11
Hauptschalter
20.2
main switch
2 4 6
L3.0 /2.0
L2.0 /2.0
Kurz- und erdschlusssicher verlegen!

to be laid short-circuit proof and protected against accidential earthing!
PE-Bus
PE
L1 L2 L3 PE
CUSTOMER
Kunde
customer
3Ph/PE/415V/50Hz
Einspeisung Betriebsspannung
U / f / P 415V/50Hz/ca. 18kW
415V/50Hz/approx. 18kW REV. DATE MADE APPVD. MEMO NO. EXPLANATION
C
C Wartsil„
Circuit diagram
Icn 36kA Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
Vollaststrom ca. 53A
ACA UNITS
full load current approx. 53A PRODUCT BJN 011-061 E 40
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-508
C
0 1 2 3 4 5 6 7 8 9
1.9/ L1 L1 /7.1
1.9/ L2 L2 /7.1
1.9/ L3 L3 /7.1
1.9/ L2.0
1.9/ L3.0
1 3 5 1 3 5
-0Q1 -230Q1
0,22-0,32A 0,9-1,25A
In:0,31A In:1,10A
2 4 6 2 4 6
PE PE
-0T1 B G PE C F -230T1 B G PE C F
100VA 400VA
415/230V 415/230V
ua vb ua vb
ub va ub va
1 1 1
-0F3 -230F4 -230F3

C 1A 2 C 3A 2 C 6A 2
230W3 /3.0
230W3K /5.0
230W03 /6.3 230W4 /4.0
230W02 /6.3 230W2 /3.0

230W2K /8.0
PE PE
-1X0 1 2 3 4 -1X2 1 2 3 4
Steuerspannung 230VAC (Stillstandsheizung) Steuerspannung 230VAC

control voltage 230VAC (space heater) control voltage 230VAC
C
C Wartsil„
Circuit diagram
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-508
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0 1 2 3 4 5 6 7 8 9
2.9/ 230W3 230W3 /6.3

2.9/ 230W2 230W2 /5.0
L1 N
-1U1
170-264VAC + GND -
24VDC
5A L+ PE L-
PE PE
24W11 /9.0
24W11K /12.0
24W10 /9.0
24W10K /9.1
Steuerspannung 24VDC
control voltage 24VDC
C
C Wartsil„
Circuit diagram
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-508
C
0 1 2 3 4 5 6 7 8 9
2.9/ 230W4
-0Q2 -0Q3
0-60øC 3 0-60øC 3
2 2
1 1
4 4
-0R2
30W L N
L1
N
PE -0M3
19/18W
PE PE
230W2T /7.4
Schrankheizung Schrankluefter
cabinet heater cabinet fan
C
C Wartsil„
Circuit diagram
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-508
C
0 1 2 3 4 5 6 7 8 9
2.9/ 230W3K 230W3K /8.0

230W3.1 /6.3
-1X2 5 6
if emergency stop
-S01
remove link
21
NotAus PE
extern 22
(Option)
emergency stop
external
(optional) -1X2 7 PE-Bus
PE
21
-1S01
NotAus 22
emergency stop
A1
-K01
A2
3.9/ 230W2 230W2 /6.3

14
14.8
12 11
14.8
Notaus
emergency stop
C
C Wartsil„
Circuit diagram
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-508
C
0 1 2 3 4 5 6 7 8 9
3.9/ 230W3 230W3 /8.0
L1.1 /1.9
L2.1 /1.9
L3.1 /1.9
5.9/ 230W3.1 230W3.1 /7.4
2.3/ 230W03 230W03 /7.4 -1X2 8 9
21 31
-1K1 -1K1
.7
22
.7
32
-S2
12 14 21
-1K10 Schlammablauf
Klappe PE
16.1 (Option)
11 22
sludge discharge
flap
(optional)
TAH -1X2 10 PE-Bus

1 3 5
-1K1 PTC
-1X0 5
.7 PE
2 4 6
95
-1F01
PE
R01 .5
96
50W
1 /9.0 PE
P1 S1 12 14
-1T1 -1K12
17.1
P2 S2 50/1A 11
2 /9.0
21
-1X0 6 PE-Bus -1X5 1 2 PE-Bus
-1S1
22
PE
PE
13 13
-1K1
-1S2
.7
14 14
PE
A1
51 X1
-1K1
.7
-0H3 T1
52 LED X2 T2 A1
-1X1 1 2 3 PE-Bus
-1K1
A2
A2
2.3/ 230W02 230W02 /7.4 -1F01

U1 V1 W1
230W02T /7.4
5.9/ 230W2 230W2 /7.4
D01 .7
95 96
.0
1 2
97 98 3 4
15kW 11.2 .1
In:26,0-28,0A 5 6
.1
PE 13 14
.8
21 22
.3
31 32
Motordrehrichtung links .3
43 44
motor rotation left 20.3
51 52
.3
63 64
11.1
71 72
Separator Stillstandsheizung Separator TAH Separator Motortemperatur 83 84
separator space heater separator TAH separator motor temperature Separator Betrieb
separator operation
C
C Wartsil„
Circuit diagram
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-508
C
0 1 2 3 4 5 6 7 8 9
6.9/ 230W3.1
L1 /2.9
L2 /2.9
L3 /2.9
6.4/ 230W03
21 31 17
-3Q1 -3Q1 -3Q1
.1 .1 .1
22 32 22 24 18
-1K10
1L1
LUB12 16.1
3L2
5L3
12A 21
-3Q1
A1 13 21 31 41 17 97
20.4
.7
.4 A2 14 22 32 42 18 98
.5
.4
12.5
.8
. . . . . -1X0 7
21 12 14
-1K13
control unit LUCA 12 FU -3S1 17.2
3-12A 22 11
In:5A . . .
R02
26W
LUFN02 PE
LU9BN11 LUA1C20
12 14 13 12 14
-3K2 -1K11
2T1
4T2
6T3
.7
-3S2 16.2
-1X0 8 PE-Bus 11 14 11
PE
PE
41 X1
-1X1 4 5 6 PE-Bus -3Q1
.1
-0H4
42 LED X2
A1 A1
-3Q1
-3K2
.1
6.4/ 230W02 A2 A2
6.4/230W02T
U1 V1 W1
6.9/ 230W2
4.9/ 230W2T
D03 .6
14
12 11
2,2kW .6
In:5,0A 24
12.4
PE 22 21
12.4
Zulaufpumpe Stillstandsheizung Zulaufpumpe Zulaufpumpe Zulaufpumpe Betrieb

feed pump space heater feed pump feed pump feed pump operation
C
C Wartsil„
Circuit diagram
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-508
C
0 1 2 3 4 5 6 7 8 9
5.9/ 230W3K
6.9/ 230W3
13 13. 13 13.
-1K18 -1K19
17.7 17.8
14 14. 14 14.
-1X2 13 14 15
V52
close
open
40
14 11
Motor valve
M
1~
1 PE
-1X2 11 12 PE-Bus
PE
2.9/ 230W2K
Stellventil - Heizmedium
C
C Wartsil„
Circuit diagram
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-508
C
0 1 2 3 4 5 6 7 8 9
3.9/ 24W10 24W10 /11.0

3.9/ 24W11 24W11 /11.0
T01
P12 P61 2x PT 100
TC
4-20mA 4-20mA
PSL/H SMS
P P
I I
2 1 1 2
0-1A
2 7+
6.2/ 1 -1X20 1 2 PE-Bus 3 4 -1X5 3 4 5 6 SC
4/11.6
8
3 9-
6.2/ 2 -1X10 3 4 PE-Bus 5 6 SC SC
4-20mA
PE 3 5 4
5/13.4
-1U3 -1U5
IAL
PT100
4-20mA
2 1
-1X3 3 4 5 6
3.9/ 24W10K 24W10K /11.0
-1A1 -1A1 -1A1 -1A1 -1A1
X1_3 X1_4 X1_6 X1_7 X1_9 X1_10 X1_12 X1_13 X1_14 X1_15
PEW752+ PEW752- PEW754+ PEW754- PEW756+ PEW756- PEW758+ PEW758- PEW760+ PEW760-
24W11K1 /21.0
24W11K1 /21.0
4-20mA = 0-50A 4-20mA = 0-120øC 0-120øC
IAL Separator Reinoel Schlammraumueberwachung PI-Regelung min/max-Temperaturueberwachung

Entleerungsueberwachung Ablaufdruck sludge space monitoring PI-control min/max-temperature monitoring
IAL separator clean oil
ejection monitoring discharge pressure
C
C Wartsil„
Circuit diagram
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-508
C
0 1 2 3 4 5 6 7 8 9
-1A1 -1A1
PAW752+ PAW752- PAW754+ PAW754-

X1_16 X1_17 X1_18 X1_19
Reserve Reserve
spare spare
C
C Wartsil„
Circuit diagram
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-508
C
0 1 2 3 4 5 6 7 8 9
9.9/ 24W10 24W10 /12.0

9.9/ 24W10K 24W10K /12.0
-1X3 7 9 11 SE -1X3 13 15
+ -
9.5/ 4
-1X10 1 2 PE-Bus -1X20 6
-1X3 1 2 SC PE-Bus
63 97
-1K1 -1F01 PE K61 +
6.7 6.5 WMS
64 98
A/Q -
SC
-1U6
1+ 2-
5+
-1X20 5 7
6-
-1X10 7 6 /15.5
4
-1X3 8 10 12 -1X3 14 16
X2_2 X2_3 X2_4 X2_5 X2_6 X2_7

E 0.0 E 0.1 E 0.2 E 0.3 E 0.4 E 0.5
-1A1 -1A1 -1A1 -1A1 -1A1 -1A1

Separator Separator Reserve Drehzahlanzeige Reserve Wasserabfuhr
Betrieb Stoerung spare Separator spare water monitoring system
separator separator speed indication
operation failure separator
(max. 8200 r.p.m.)

9.9/ 24W11 24W11 /16.0
C
C Wartsil„
Circuit diagram
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-508
C
0 1 2 3 4 5 6 7 8 9
11.9/ 24W10 24W10 /14.0

11.9/ 24W10K 24W10K /13.0
-1X3 17 19
L43 3
22 24 97
FTL 260
PE
-3K2 -3Q1
7.7 7.1
21 98
2 1
-1X3 18 -1X3 20 21 PE-Bus 22
PE
X2_8 X2_9 X2_12 X2_13 X2_14 X2_15

E 0.6 E 0.7 E 1.0 E 1.1 E 1.2 E 1.3
-1A1 -1A1 -1A1 -1A1 -1A1 -1A1

Reserve LSHH Schlammtank Zulaufpumpe Zulaufpumpe Reserve Reserve
spare LSHH sludge tank Betrieb Stoerung spare spare
feed pump feed pump
operation failure
3.9/ 24W11K 24W11K /13.0
C
C Wartsil„
Circuit diagram
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-508
C
0 1 2 3 4 5 6 7 8 9
24W10K1 /18.0
12.9/ 24W10K 24W10K /14.0
-1X3 25 26 31 32 34 36
9.5/ 5
-1X10 8 9
L44 2
FTL 260
PE
3 1
-1X10 10 11
7 /15.2
-1X3 27 28 PE-Bus 30 29 33 35 37 38
PE
X2_16 X2_17 X2_18 X2_19

E 1.4 E 1.5 E 1.6 E 1.7
-1A1 -1A1 -1A1 -1A1

LSH Schlammtank Reserve Reserve Reserve
LSH sludge tank spare spare spare
12.9/ 24W11K 24W11K /15.0
C
C Wartsil„
Circuit diagram
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-508
C
0 1 2 3 4 5 6 7 8 9
12.9/ 24W10
13.9/ 24W10K 24W10K /21.0
-1X3 39 41 43 45 47 49 51
12 14
-K01
5.5
11
-1X3 40 42 44 46 48 50 52
X1_22 X1_23 X1_24 X1_25 X1_26 X1_27 X1_28 X1_29

E 2.0 E 2.1 E 2.2 E 2.3 E 2.4 E 2.5 E 2.6 E 2.7
-1A1 -1A1 -1A1 -1A1 -1A1 -1A1 -1A1 -1A1

Reserve Reserve Reserve Reserve Reserve Reserve Reserve Notaus
spare spare spare spare spare spare spare emergency stop
C
C Wartsil„
Circuit diagram
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-508
C
0 1 2 3 4 5 6 7 8 9
-1A1 -1A1 -1A1 -1A1 -1A1 -1A1
A 0.0 A 0.1 A 0.2 A 0.3 A 0.4 A 0.5

X2_22 X12_2 X12_3 X12_4 X12_5 X12_6
PE PE
-1X4 1 PE-Bus 3 4 PE-Bus -1X4 6 7
PE
PE
-1X10 16 PE-Bus 18
PE
-1X10 15 PE-Bus 12 PE-Bus -1X20 8 PE-Bus 11 PE-Bus
+ + + + +
V33 V27A V27B V62 V61

- - - - -
-1X20 9 10
11.7/6
-1X10 14 13 -1X10 17
13.5/ 7
-1X4 2 5 -1X4 8
13.9/ 24W11K 24W11K /17.0
Separator Fuell- und Steuerwasser Ventil Reserve Kreislaufventil Wasserabfuhrventil

Zulaufventil Verdraengungswasser operating water valve spare circulation valve water discharge valve
separator fill- and
feed valve displacement water
C
C Wartsil„
Circuit diagram
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-508
C
0 1 2 3 4 5 6 7 8 9
-1A1 -1A1
A 0.6 A 0.7
X2_28 X2_29
A1 A1
-1K10 -1K11
A2 A2
11.9/ 24W11 24W11 /17.0

14 14
6.4 7.8
12 11 12 11
6.4 7.8
24 24
7.6 20.1
22 21 22 21
7.5 20.1
Lampentest Sammelalarm
lamp test common alarm
C
C Wartsil„
Circuit diagram
Power Plants
Systems GmbH
D-59302 Oelde
WITH OSE 40-0196
CORPORATION
ACA UNITS
PROJ. NO.
ASLY. DRG
CHKD.
NO. NO.
0
8106-2003-508
C
0 1 2 3 4 5 6 7 8 9
-1A1 -1A1 -1A1 -1A1 -1A1 -1A1 -1A1 -1A1
A 1.0 A 1.1 A 1.2 A 1.3 A 1.4 A 1.5 A 1.6 A 1.7

X2_32 X2_33 X2_34 X2_35 X2_36 X2_37 X2_38 X2_39
PE
-1X4 9 PE-Bus
V35
-
A1 A1 -1X4 10 A1 A1
-1K12 -1K13 -1K18 -1K19

A2 A2 A2 A2
16.9/ 24W11
15.9/ 24W11K 24W11K /18.0
14 14 13 14 13 14
6.7 7.8 8.1 8.2
12 11 12 11
6.7 7.8
Separator Aus Zulaufpumpe Ventil Reserve Reserve Reserve Stellventil Stellventil

separator off Ein/Aus Schlammpumpe spare spare spare Auf Zu
feed pump valve control valve control valve
on/off sludge pump open close
C
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Circuit diagram
Power Plants
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WITH OSE 40-0196
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PROJ. NO.
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8106-2003-508
C
0 1 2 3 4 5 6 7 8 9
Q01
4-20mA
FI
P
I
2 1
-1X5 7 8
13.9/ 24W10K1
17.9/ 24W11K 24W11K /19.0
-1A2 -1A2 -1A2 -1A2
2 5 7 10 12 15 17 20
PEW762+ PEW762- PEW764+ PEW764- PEW766+ PEW766- PEW768+ PEW768-
FI Durchflussmesser Reserve Reserve Reserve

Zulauf spare spare spare
FI flow meter
feed
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CORPORATION
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0 1 2 3 4 5 6 7 8 9
18.9/ 24W11K 24W11K /21.0
-1A2 -1A2 -1A2 -1A2
22 25 27 30 32 35 37 40
PEW770+ PEW770- PEW772+ PEW772- PEW774+ PEW774- PEW776+ PEW776-
Reserve Reserve Reserve Reserve

spare spare spare spare
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22 24 12 14 43 13
-1K11 -Q1 -1K1 -3Q1
16.2 1.2 6.7 7.1
21 11 44 14
PE
-1X6 1 2 3 4 5 6 PE-Bus -1X6 7 8
CUSTOMER
PE
Sammelalarm Separator Zulaufpumpe Reserve

common alarm Betrieb Betrieb spare
separator feed pump
operation operation
max. Schaltstrom 5A (115V/230VAC)

max. switch current 1A (24VDC)
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Circuit diagram
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0 1 2 3 4 5 6 7 8 9
14.9/ 24W10K
19.9/ 24W11K
9.9/ 24W11K1
9.9/ 24W11K1
PE
X1_20
X1_30
X2_20
X2_21
X2_30
X2_31
X2_40
X2_1
PE
L+/1
M/2
L+
M
L+
MANA
4M
1L+
1M
2L+
2M
3L+
3M
M
OP177B color
Touch panel
touch panel
6ES7331-1KF01-0AB0
Analogeingaenge
analog inputs
PEW 762 - 776

MPI
MPI
CPU 313C
-1A1 -1A2 -1A0
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Funktionszeichen Seite Pfad Bestell-Nr. Benennung Typ Technische Daten Fabrikat

function sign page path order no. designation type technical data make
-. 5/1.0 Gehaeuse, lackiert AE1090.500 600x1000x250mm Rittal

cabinet, varnished RIT.AE1090500
-. 5/1.0 0005-1412-000 Tuerarretierung SZ2519.000 for cabinet AE Rittal

door locking device RIT.SZ2519000
-. 5/1.0 Kleinmaterial Kleinmaterial Schaltschrank KLEINMATERIAL Plenge

incidentals control cabinet PLE.KLEINMATERIAL
-. 5/1.0 Resopalschild RESOPALSCHILD100/130 100/130x25mm Kaiser

resopal plate KAI.RESOPALSCHILD100/130
-. 5/1.0 Aderkennzeichnung ADERKENNZEICHNUNG conductor marking Plenge

conductor marking PLE.ADERKENNZEICHNUNG
-Q1 5/1.1 Leistungsschalter NSX100F+TM63D Iu.: 44...63A Groupe Schneider

circuit breaker GSD.NSX100F+TM63D
-Q1 5/1.1 Drehantrieb mit Tuerkupplung LV429338 standard Groupe Schneider

rotation drive with door coupl. GSD.LV429338 handle colour: BK
for NSX100/160/250
-Q1 5/1.1 Klemmenabdeckung LV429515 3P / short Groupe Schneider
cover of terminals GSD.LV429515 for NSX100/160/250
-Q1 5/1.1 0005-1438-200 Hilfsschalter 29450 1 c/o contact Groupe Schneider

auxiliary switch GSD.29450 for NS
-0T1 5/2.1 0005-0551-470 Steuerspannungstransformator ISTU-100 Prim.: 200-560V Ismet

control voltage transformer ISM.ISTU-100 Sec.: 115/230V, 100VA
-0Q1 5/2.1 0005-4390-480 Leistungsschalter 3RV1421-0DA10 0,22-0,32A Siemens

circuit breaker SIE.3RV1421-0DA10 Ue/Ui=690V, 50/60Hz
size: S0
-0F3 5/2.1 0005-1621-010 Sicherungsautomat EP61 C01 1A AEG
miniature circuit breaker AEG.566512 1 pole
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-230T1 5/2.6 0005-0551-490 Steuerspannungstransformator ISTU-400 Prim.: 200-560V Ismet

control voltage transformer ISM.ISTU-400 Sec.: 115/230V, 400VA
-230Q1 5/2.6 0005-4390-480 Leistungsschalter 3RV1421-0KA10 0,9-1,25A Siemens

circuit breaker SIE.3RV1421-0KA10 Ue/Ui=690V, 50/60Hz
size: S0
-1U1 5/3.1 0005-1407-020 Einphasennetzgeraet 6EP1333-2AA01-0AA0 Prim.: 120/230V, 50/60Hz Siemens

single phase power supply SIE.6EP1333-2AA01-0AA0 Sec.: 24VDC, 5A
-0Q2 5/4.1 Thermostat FLZ 510 230V, 50/60Hz Pfannenberg

thermostat PFA.FLZ510 0øC - +60øC
max. 250VAC
-0R2 5/4.2 Schrankheizung FLH 030 30W Pfannenberg
cabinet heater PFA.FLH030 110-250V, 50/60Hz
-0Q3 5/4.3 Thermostat FLZ 510 230V, 50/60Hz Pfannenberg

thermostat PFA.FLZ510 0øC - +60øC
max. 250VAC
-0M3 5/4.4 0005-1409-320 Filterluefter PF 22.000 207-253V, 50/60Hz Pfannenberg
filter fan PFA.PF22.000 19/18W, 44/52mü /h
IP54, RAL 7035
-0M3 5/4.4 0005-1409-230 Austrittsfilter PFA 20.000 145x145x26mm Pfannenberg
discharge filter PFA.PFA20.000
IP54, RAL 7035

-1S01 5/5.5 0005-4393-000 Pilzdrucktaster komplett K_3SB3000-1HA20-A colour: RD, locking, 40mm Siemens
mushroom push button complete SIE.3SB3000-1HA20-A 1NO/1NC
-1S01 5/5.5 Schutzkragen (SIGNUM) 3SB3921-0AK colour: YE Siemens

protective collar (Signum) SIE.3SB3921-0AK
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PROJ. NO.
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8106-2003-808
APPVD. KA 2 /8 REV.
C
0 1 2 3 4 5 6 7 8 9
WSO_O_W1.sko 25.11.98

-K01 5/5.5 0005-4033-110 Koppelrelais PLC-RSC-230UC/21 230VAC/DC Phoenix Contakt

interface relay PHO.PLC-RSC-230UC/21 1 c/o contact
-1T1 5/6.1 0005-0924-220 Stromwandler TAID/50/1 50/1A IME

current transformer IME.TAID/50/1
-0H3 5/6.3 0005-1553-080 Leuchtmelder komplett K_3SB3001-6AA40/LED/230 colour: GN Siemens

pilot light complete SIE.3SB3001-6AA40/LED/230
230VAC/LED
-1F01 5/6.5 0005-1100-070 Motorvollschutzrelais 3RN1010-1CM00 196-253V, 50/60Hz Siemens
motor protection relay SIE.3RN1010-1CM00 1NO/1NC
-1S1 5/6.7 0005-1414-110 Drucktaster komplett K_3SB3000-0AA21-C colour: RD Siemens

push button complete SIE.3SB3000-0AA21-C 1NC
-1S2 5/6.7 0005-1414-100 Drucktaster komplett K_3SB3000-0AA11-B colour: BK Siemens

push button complete SIE.3SB3000-0AA11-B 1NO
-1K1 5/6.7 0005-4382-100 Leistungsschuetz 3RT1035-1AL24 196-253V, 50/60Hz Siemens

contactor SIE.3RT1035-1AL24 2NO/2NC
size: S2 (up to 18,5kW)
-1K1 5/6.7 0005-4399-120 Hilfsschalterblock 3RH1921-1EA11 1NO/1NC Siemens
auxiliary switch block SIE.3RH1921-1EA11 side extension
-1K1 5/6.7 0005-0915-170 RC-Glied 3RT1936-1CD00 127-240VAC Siemens

RC-element SIE.3RT1936-1CD00
-3Q1 5/7.1 0005-1730-000 Grundgeraet LUB12 12A with screw clamp Groupe Schneider
basic device GSD.LUB12
<=440V/12A
-3Q1 5/7.1 0005-1730-130 Steuereinheit Standard LUCA12FU f. basic device 12A + 32A,3-12A,
Groupe Schneider
control unit standard GSD.LUCA12FU 400/415V, 5,5KW
-3Q1 5/7.1 0005-1730-410 Hilfsschaltermodul f. Grundgeraet LUFN02 2NC Groupe Schneider

auxiliary switch module f. basic deviceGSD.LUFN02 24-240VAC/DC, 5A
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8106-2003-808
APPVD. KA 3 /8 REV.
C
0 1 2 3 4 5 6 7 8 9
WSO_O_W1.sko 25.11.98

-3Q1 5/7.2 0005-1730-310 Hilfsschalter LUA1C20 for basic device Groupe Schneider
auxiliary switch GSD.LUA1C20 2NO
-0H4 5/7.5 0005-1553-080 Leuchtmelder komplett K_3SB3001-6AA40/LED/230 colour: GN Siemens

pilot light complete SIE.3SB3001-6AA40/LED/230
230VAC/LED
-3S1 5/7.7 0005-1414-110 Drucktaster komplett K_3SB3000-0AA21-C colour: RD Siemens
push button complete SIE.3SB3000-0AA21-C 1NC
-3S2 5/7.7 0005-1414-100 Drucktaster komplett K_3SB3000-0AA11-B colour: BK Siemens

push button complete SIE.3SB3000-0AA11-B 1NO
-3K2 5/7.7 0005-4033-120 Koppelrelais PLC-RSC-230UC/21-21 230VAC/DC Phoenix Contakt

interface relay PHO.PLC-RSC-230UC/21-21 2 c/o contact
-1U3 5/9.1 0005-3482-070 Messumformer WAS1CMA 1A AC/4-20MA 24VDC Weidmueller

measuring transducer WEI.WAS1CMA1AAC/4-20MA 0-1A = 4-20mA
-1U5 5/9.5 0005-3482-060 Messumformer MCZ PT100/3CLP 24VDC Weidmueller

measuring transducer WEI.MCZ PT100/3CLP 0-120øC = 4-20mA
-1U6 5/11.4 0005-4509-000 Sensor-Endstufenklemme KCD2-E2 inp. for sensors NAMUR Pepperl & Fuchs
sensor-power amplifier terminal PUF.KCD2-E2 24VDC
-1K10 5/16.1 0005-4033-080 Koppelrelais PLC-RSC-24DC/21-21 24VDC Phoenix Contakt

interface relay PHO.PLC-RSC-24DC/21-21 2 c/o contact
-1K11 5/16.2 0005-4033-080 Koppelrelais PLC-RSC-24DC/21-21 24VDC Phoenix Contakt

interface relay PHO.PLC-RSC-24DC/21-21 2 c/o contact
-1K12 5/17.1 0005-4033-040 Koppelrelais PLC-RSC-24DC/21 24VDC Phoenix Contakt

interface relay PHO.PLC-RSC-24DC/21 1 c/o contact
-1K13 5/17.2 0005-4033-040 Koppelrelais PLC-RSC-24DC/21 24VDC Phoenix Contakt

interface relay PHO.PLC-RSC-24DC/21 1 c/o contact
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Parts list
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WITH OSE 40-0196
CORPORATION
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PROJ. NO.
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NO. NO.
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8106-2003-808
APPVD. KA 4 /8 REV.
C
0 1 2 3 4 5 6 7 8 9
WSO_O_W1.sko 25.11.98

-1K18 5/17.7 0005-4033-140 Koppelrelais PLC-RSC-24DC/1IC/ACT 24VDC Phoenix Contakt

interface relay PHO.PLC-RSC-24DC/1IC/ACT 1NO
-1K19 5/17.8 0005-4033-140 Koppelrelais PLC-RSC-24DC/1IC/ACT 24VDC Phoenix Contakt

interface relay PHO.PLC-RSC-24DC/1IC/ACT 1NO
-1A2 5/21.0 0005-4281-030 Analog Eingangsmodul 6ES7331-1KF01-0AB0 input mA/mV/PT 100 Siemens
analog input module SIE.6ES7331-1KF01-0AB0 Nachfolgetyp: 6ES7331-1KF02-0AB0
-1A2 5/21.0 0005-4050-722 Frontstecker 6ES7392-1AM00-0AA0 40 pole Siemens

front connectors SIE.6ES7392-1AM00-0AA0 screw connector
-1A1 5/21.0 0005-4050-720 Zentralbaugruppe 6ES7313-5BF03-0AB0 CPU 313 Siemens

CPU module SIE.6ES7313-5BF03-0AB0 1 interface MPI
multipointable
-1A1 5/21.0 0005-4050-721 Memory Card 6ES7953-8LG11-0AA0 128 kByte Siemens
memory card SIE.6ES7953-8LG11-0AA0 MMC
-1A1 5/21.0 0005-4050-722 Frontstecker 6ES7392-1AM00-0AA0 40 pole Siemens

front connectors SIE.6ES7392-1AM00-0AA0 screw connector
-1A1 5/21.0 0005-4050-760 Profilschiene 6ES7390-1AE80-0AA0 482mm Siemens

profile bar SIE.6ES7390-1AE80-0AA0
-1A1 5/21.0 0005-4050-723 Steckleitung 6ES7901-0BF00-0AA0 5mtr. Siemens

plug line SIE.6ES7901-0BF00-0AA0
-1A0 5/21.0 0005-4050-710 Prozessanzeige OP177 B WS 6AV6642-0DA01-1AX0 5,7" bluemode STN display Siemens
process display OP177 B WS SIE.6AV6642-0DA01-1AX0 24VDC
-1A0 5/21.0 Memory Card 6AV6671-1CB00-0AX2 128 MByte Siemens

memory card SIE.6AV6671-1CB00-0AX2 MMC
-1X0 5/21.7 0005-3503-890 Reihenklemme WDU2,5 2,5mmý Weidmueller

terminal WEI.WDU2,5
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8106-2003-808
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0 1 2 3 4 5 6 7 8 9
WSO_O_W1.sko 25.11.98

-1X1 5/21.7 0005-3504-890 Reihenklemme WDU4 4mmý Weidmueller

terminal WEI.WDU4
-1X1 5/21.7 Reihenklemme WDU16/ZA 16mmý Weidmueller

terminal WEI.WDU16ZA

terminal WEI.WDU2,5

terminal WEI.WDU2,5

terminal WEI.WDU2,5

terminal WEI.WDU2,5

terminal WEI.WDU2,5
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=Glands 5/21.9 0005-4486-930 Verschraubung 50.616 PA/FL M16x1,5, halogen free Jacob
cable gland PLE.M16X1,5/RAL7032 5-10mm
RAL 7032
=Glands 5/21.9 0013-0130-630 Gegenmutter 50.216M M16x1,5 Jacob
counter nut PLE.M16X1,5/GEGEN/NICKEL
brass nickeled
RAL 7032
brass nickeled
RAL 7032
brass nickeled
=Glands 5/21.9 0005-4442-630 Blindstopfen 10.1615M/G M16x1,5 Jacob
dummy plug PLE.M16X1,5/BLIND/NICKEL IP65
brass nickeled
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=Additions 5/21.9 0005-1554-000 Kabelbezeichnung WKS 11/54 polyamid Weidmueller

cable designation WEI.WKS11/54 PVC-cable-describe
1 card = 8 pieces
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C
Order sheet
Inquiry sheet
To: Mechanical Separation

GEA Westfalia Separator
Osterrade 18 a · 21031 Hamburg (Germany)
Fax +49 (0) 40 / 73-80585
WS-Order-No.:
Project:
NB No.:
Model:
Please use this fax form to order / inquire spare parts. Add also a copy of the spare parts list
(previous page(s)) where you can mark the required parts.
Orderer:
company/
name:
street.:
city:
phone:
fax:
Invoice recipient: (if deviating)

company/
name:
street.:
city:
phone:
fax:
Delivery address: (if deviating)

company/
name:
street.:
city:
phone:
fax:
Date: signature:
1 Mechanical Separation / GEA Westfalia Separator

WS-Order-No.:
Project:
NB No.:
Model:
required Qty.* Designation WS Part-No.

Qty.
• Use only genuine spare parts from

Westfalia Separator.
Otherwise safety risks may arise.
2 Mechanical Separation / GEA Westfalia Separator

4 Control Unit
4.1 Control Unit

E-40
4.2 Adjustment values and fault signals
Einstellwerte u. Betriebstörungen

Instruction manual
Designation Control system for OSE centrifuges
Type E40
No. 8555-9001-200
Edition 0309

2 8555-9001-200 / 0309
TRANSLATION OF ORIGINAL INSTRUCTION MANUAL

the documentation. They can be addressed to:
Werner-Habig-Straße 1 · 59302 Oelde (Germany)
Phone: +49 2522 77-0 · Fax: +49 2522 77-0

8555-9001-200 / 0309 3
GEA Westfalia Separator Systems GmbH

59302 Oelde, Germany
Typ
............................................................................................
Type
Prüf-Nr.
............................................................................................
Control No.
Bemessungsspannung
......... V, 3/AC ................. Hz
Nominal voltage
Steuerspannung
.............. VAC ................. Hz ............... VDC
Control voltage
Volllaststrom Schutzart
................... A
Full-load current Enclosure IP …..................
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.
Teil-Nr.
.........................................................................
Part No.
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 nameplate must be filled in by the user.

Please copy the data from the nameplate inside the control cabinet.

4 8555-9001-200 / 0309
For your safety

symbol -
otherwise danger to life!

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

tionally to the operation of the control unit. The plant operator must
ensure 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 accor-
dance with the rules and regulations of the VDE (Verband Deutscher
Elektrotechnik / 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.

8555-9001-200 / 0309 5
• 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 ma-
nual.
• Liability for the function of the unit passes to the owner.

Liability for the function of the unit 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.

6 8555-9001-200 / 0309
1.1 Preface................................................................................................... 10
1.2 Correct usage ........................................................................................ 11
1.3 Non-compliance with the intended use .................................................. 12
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 “Emergency-Off" .................................................................. 19
1.5.6 Voltage cutoff during operation .............................................................. 20
1.5.7 Maintenance and repair ......................................................................... 21
1.6 Explosion protection .............................................................................. 22
1.6.1 Classification of the centrifuge / plant .................................................... 22
1.6.2 Obligations of the operator .................................................................... 23
1.6.3 Standards and guidelines ...................................................................... 23
1.7 Care instructions .................................................................................... 25
1.8 Storage .................................................................................................. 25
1.8.1 After delivery .......................................................................................... 25
1.9 Disposal ................................................................................................. 26
2 Equipment description 27
2.1 Function ................................................................................................. 28

2.2 Performance features ............................................................................ 29
2.3 Areas of application ............................................................................... 29
2.4 Functional layout diagram...................................................................... 30
2.5 Technical Data ....................................................................................... 31
2.5.1 control .................................................................................................... 31
2.5.2 Control cabinet ....................................................................................... 32
2.5.3 Digital inputs/outputs (DI/DO) ................................................................ 34
2.5.4 Analog inputs and outputs (AI/AO) - 4 – 20 mA .................................. 36
2.6 Configuration ......................................................................................... 37
2.6.1 Frontal view control cabinet ................................................................... 37
2.6.2 Inner view control cabinet ...................................................................... 38
2.6.3 Special versions ..................................................................................... 38
3 Operation 39
3.1 Getting to know the operating elements ................................................ 40

3.1.1 Softkeys and their symbols .................................................................... 41
3.1.2 System keys (Touch) ............................................................................. 43
3.1.3 Edittext, numerical values or fields ........................................................ 45
3.2 Password protection .............................................................................. 46
3.3 Switch oncontrol unit .............................................................................. 46
3.3.1 Overview of the menus .......................................................................... 48
3.3.2 Main menu (HOME) ............................................................................... 49
3.4 Process diagrams .................................................................................. 50
3.4.1 Process overview ................................................................................... 50

8555-9001-200 / 0309 7
3.4.2 Detailed views ........................................................................................ 52

3.4.3 Separator control area ........................................................................... 53
3.4.4 Graphic representation for current and speed ....................................... 56
3.4.5 UNITROL Range ................................................................................... 57
3.4.6 Light sequence area .............................................................................. 58
3.4.7 Sludge tank range .................................................................................. 59
3.4.8 Heater range .......................................................................................... 60
3.4.9 Symbols in all process pages ................................................................ 62
3.5 Temperaturecontroller ........................................................................... 63
3.5.1 Controller curve (graphic representation) .............................................. 65
3.6 Commissioning data and service addresses ......................................... 66
3.6.1 Commissioning data .............................................................................. 66
3.6.2 Service addresses worldwide ................................................................ 67
3.6.3 Local date and time adjustment ............................................................. 68
3.7 Timer ...................................................................................................... 70
3.7.1 Modify time value (example) .................................................................. 71
3.7.2 Timer without password (user times) ..................................................... 72
3.7.1 Timer with Password ............................................................................. 73
3.7.2 Counter .................................................................................................. 74
3.8 Digital/analog inputs/outputs.................................................................. 76
3.8.1 Analog Input 1 - AI-0.0 ......................................................................... 77
3.8.2 Analog input 2 - AI-0.1 ......................................................................... 78
3.8.3 Analog input 3 - AI-0.2 ......................................................................... 79
3.8.4 Analog input 4 - AI-03 .......................................................................... 80
3.8.5 Analog input 5 - AI-AIR (P T100 - Dire c t in p u t) .................................. 81
3.8.6 Analog outputs ....................................................................................... 82
3.8.7 Status of the digital inputs/outputs ......................................................... 83
3.9 Operating hours and settings................................................................. 85
3.9.1 Settings .................................................................................................. 86
3.10 Separator faults ..................................................................................... 88
3.10.1 Fault messages ..................................................................................... 88
3.10.2 Displaying queued fault messages ........................................................ 89
3.10.3 Displaying the fault message buffer ...................................................... 90
3.10.4 Register alarm messages ...................................................................... 91
3.10.5 Status and fault indication .................................................................. 94
3.11 SwitchMicro Memory Card (MMC) ........................................................ 95
3.12 CPU Master Reset ................................................................................. 96
3.13 LoadNew Visualisation .......................................................................... 97
4 Maintenance and servicing 101
4.1 PreventingAccidents ........................................................................ 102

4.1.1 Demands on the operating and maintenance personnel ..................... 102
4.1.2 Spare part requirements ...................................................................... 103
5 Installation - Electrical connection 105
5.1 Connect control unit ............................................................................. 106

5.2 Electrical connection ............................................................................ 107
5.3 Fuse terminals ..................................................................................... 107
5.4 Central control via potential-free contacts ........................................... 108

8 8555-9001-200 / 0309
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note

8555-9001-200 / 0309 9
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
1.6 Explosion protection .............................................................................. 22
1.6.1 Classification of the centrifuge / plant .................................................... 22
1.6.2 Obligations of the operator .................................................................... 23
1.6.3 Standards and guidelines ...................................................................... 23
1.7 Care instructions .................................................................................... 25
1.8 Storage .................................................................................................. 25
1.8.1 After delivery .......................................................................................... 25
1.9 Disposal ................................................................................................. 26

10 8555-9001-200 / 0309
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
processing, please state when or-
dering spare parts:
– type (1)
– control no. (2)
– circuit-diagram no. (3)
Fig. 2 Example

8555-9001-200 / 0309 11
1.2 Correct usage

The control system
• is used to ensure automatic ejection and process monitoring of mineral-oil se-
parators of the 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 agree-
ments.
The electronic control system triggers total ejections of the bowl at adjustable in-
tervals with or without displacement of the product from the bowl.
The following ejections can be selected for the separators stated:
– Partial ejections
Partial ejection of the bowl means partial emptying oft he solids space oft
he 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)!
– preselectable 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:
– Water content monitoring system – WMS (Water Content Monitoring Sys-
tem)
– Sludge space monitoring system– SMS (Sludge Space Monitoring System)
Separators of the new D or 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
For additional information on correct operation of the control unit, please refer to
the electrical documentation.
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!

12 8555-9001-200 / 0309
1.3 Non-compliance with the intended use

Any use that deviates from the intended use is considered to be non-
compliant.
The control unit 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 control unit 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
Non-compliance with the intended use

• can cause severe damage to the control system, the separator and other
plant components!
• can mean danger to the operator’s and other people’s life and limb!

8555-9001-200 / 0309 13
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 Example of markings on a control unit
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.

14 8555-9001-200 / 0309

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
via the main switch.
from being accidentally switched on.
Danger due to electrical voltage!

Before working on electrical separa-

tor/plant components:
Fig. 5
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.
• Take adequate preventive measures according to the national provisions (in
Deutscher Elektriker / Association of German Electrical Engineers) or of the
local electric power company.
specialists).
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.

8555-9001-200 / 0309 15
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:
The circuits marked in this way can
switch is off!
Fig. 6 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. 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

16 8555-9001-200 / 0309
1.5 Operations on the control system
The control system works reliably,

provided 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 se-
parator plant requires specialized knowledge!
CAUTION!

who
ing.
The operator of the separator, the control system or the separator plant
• must be sure that the personnel have read and understood the manuals ne-
cessary to carry out their work.
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.

8555-9001-200 / 0309 17

Separator! The original spare parts are listed in
the circuit diagram. The circuit diagram is lo-
cated on the control cabinet door.
– safety risks,
– reduced durability of these parts,
– reduced availability of the control unit
Fig. 10
for the responsible persons. In such cases,
ranty claims.

cian!
Separator.
Fig. 11

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

18 8555-9001-200 / 0309
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 Example
When unusual noises or vibrations

occur 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
separator has come to a standstill.
Fig. 13
• 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. 14

8555-9001-200 / 0309 19
1.5.5 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
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. 15 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.

Fig. 16 Example 2

20 8555-9001-200 / 0309
1.5.6 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
automatically.

off”.
Fig. 17

8555-9001-200 / 0309 21
1.5.7 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 section1.5.2).
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 ma-
nual.
Fig. 18

22 8555-9001-200 / 0309
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. 19
• The operation of centrifuges/control units in "zone 0" areas, i.e. where a

dangerous explosive atmosphere prevails continuously or for long pe-
riods or frequently is not permitted!
• Operation of the centrifuges / control systems in
– areas of “zone 1”, i.e. in areas in which a dangerous explosive atmosphere
is occasionally present,
– areas of “zone 2”, i.e. in areas where a dangerous explosive atmosphere is
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 electric apparatus of the centrifuge/plant, i.e. motor controls, valve con-
trols, electric heaters, heater control units, electrically operated valves must
be protected accordingly or, if in standard design, must be installed in a sepa-
rate room outside the explosion-hazarded area.
• Supervisory equipment on the centrifuge such as pressure switches, flow de-
tectors and temperature switches must be connected to intrinsically safe
Eex(i) electric circuits.
• In the area close to the centrifuge/control system, take the preventive meas-
ures 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.

8555-9001-200 / 0309 23
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
• 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

24 8555-9001-200 / 0309
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, ac-
tuators.
• 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”

8555-9001-200 / 0309 25
1.7 Care instructions
ATTENTION! Operating error!

• Only clean control unit and control cabinet when switched off
This insures that functions are not unintentionally activated by touching keys.
• Do not clean the control unit and control cabinet with compressed air or
steam jet.
• Do not use corrosive or acidic solvents or abrasives.
Co n d itio n s fo r c le a n in g
• Use a damp cleaning cloth.
• Only use rinsing agents or foaming screen cleaners.
P ro c e d u re
• Switch off control unit and control cabinet.
• Spray cleaning agent on cloth.
Do not spray directly on control unit or control cabinet!
• Clean control unit and control cabinet.
• Wipe control unit display from screen edge toward centre.
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 bis + 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 bis +50 °C (41 – 122 °F)
IMPORTANT:
A storage time of more than 12 months of control system is only allowed after
consulting the manufacturer.

26 8555-9001-200 / 0309
1.9 Disposal
When the equipment is no longer 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.
responsible
ENVIRONMENTAL PROTECTION!
Be sure to adhere to applicable environmental protection legislation!
More information on disposal matters can be obtained from local authorities.

8555-9001-200 / 0309 27
2 Equipment description
2.1 Function ................................................................................................. 28

2.2 Performance features ............................................................................ 29
2.3 Areas of application ............................................................................... 29
2.4 Functional layout diagram...................................................................... 30
2.5 Technical Data ....................................................................................... 31
2.5.1 control .................................................................................................... 31
2.5.2 Control cabinet ....................................................................................... 32
2.5.3 Digital inputs/outputs (DI/DO) ................................................................ 34
2.5.4 Analog inputs and outputs (AI/AO) - 4 – 20 mA .................................. 36
2.6 Configuration ......................................................................................... 37
2.6.1 Frontal view control cabinet ................................................................... 37
2.6.2 Inner view control cabinet ...................................................................... 38
2.6.3 Special versions ..................................................................................... 38

28 8555-9001-200 / 0309
2.1 Function
The illuminated graphic display provides information on the functional conditions
or faults prevailing on the separator and - depending on program adjustment -
displays 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.
Additional components for u n itro lplus are:
– circulation and water discharge valve,
– water sensor,
– and/or pressure (pressure switch/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 sludge tank
– Min/max level switch for controlling a sludge pump
– PI software controller with PT100 sensor
– Motor adjustment valve for clean-oil temperature controller
– klaxon for audible alarm-signalling
The standard control system is designed for individual control of centrifugal se-
parators or clarifiers.
If required, in case of two-stage HFO treatment, serial 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.
Abnormal plant conditions are stored in the control unit and can be retrieved and
printed out (optional) at any time.
Software allocation to the corresponding separator unit is done at the factory,
using a password-protection function.
The illuminated graphic display provides information on operation and fault con-
ditions of the separator unit and – depending on plant design – displays the cor-
responding process data and images.
IMPORTANT: The operator is not authorized to carry out program modifica-

tions!
The operator can make the following settings by means of the keypad:
– machine-specific program selection
– Timer values
– counter value settings

8555-9001-200 / 0309 29
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 serial opera-

tion (...-91-...).
Single or serial (-01-) The separator is operated with activated water
content monitoring system (…-01-…).
(WMS)
Single or serial (-01/36-) The separator is used for heavy fuel oil treat-
ment, with activated water content monitoring
(WMS/SMS -HFO)
system (...-01-...) and sludge tank monitoring
system (...-36-...).
Single or serial (-01/96-) The separator is used for lube oil treatment,
with activated water content monitoring system
(WMS/SMS -LO)
(...-01-...) and sludge tank monitoring system
(...-96-...).

30 8555-9001-200 / 0309
2.4 Functional layout diagram

Important:
Depending on the preconfiguration, representation of the pressure switch (pres-
sure switch/transmitter) can vary.
Fig. 20 Functional layout diagram (example)
A Water feed
B Clean oil discharge
C Clean oil feed
1 Water pressure reducer

2 Feed assembly with solenoid valve for filling-, displacement-, and op-
erating water
3 Control system and motor starter for separator
– Motor starter for feed pump
– Motor starter for sludge pump
4 Terminal box (fitted to separator)

5 Water detector (WMS sensor)
6 Circuit valve
7 PSL pressure switch for sludge space monitoring (analog representa-
tion)
8 Water discharge valve
9 Pneumatic 3/2-way valve with manual override and solenoid valve fon
control air (built into the clean oil feed to separator)
10 PSL pressure switch for clean oil discharge (analog representation)
11 PSH pressure switch for clean oil discharge (analog representation)

8555-9001-200 / 0309 31
2.5 Technical Data
2.5.1 control
Operator Panel (HMI – Human Machine Interface)
Part-No. see circuit diagram in control cabinet

Installation/cutout dimensions 228 x 195 mm (toleranc +1 mm)
(Width x Height)
Weight approx. 1000 g
Display type LCD-STN
with background illumination
Active display field 115.18 mm x 86.38 mm (5.7")
Colours, presentable on display 256 colours
Contrast adjustment yes
Input unit Touch screen, analog, resistive foil-
protected keyboard
Supply voltage DC +24 V
20.4 V to 28.8 V (–15 %, +20 %)
Interfaces RS 422/RS 485 (IF 1B) Sub D socket,
9-pole, with self-securing lock nut
Standard USB plug
RJ45 plugin connector
Memory device Plug-in Micro Memory Card (MMC),
128 MBytes
Software WinCC flexible 2007
Enclosure Front panel in built-in condition
– IP65
– NEMA 4X/NEMA 12
(for internal use only)
Rear panel
– IP20
Protection against contact with standard
test probes.
There is no protection provided against
water inrush!

32 8555-9001-200 / 0309
CPU (Central Processing Unit)

Fitting dimensions 120 x 125 x 130 mm
(width x height x depth)
Weight 660 g
Supply voltage DC 24 V, Range DC 20.4; DC 28.8 V
Typical current consumption (at 150 mA
idle)
Typical switch-on current 11 A
Current consumption (nominal) 700 mA
Inputs 24 digital, DC 24 V
4 analog, 4-20 mA / 0-10 V
1 PT 100
Outputs 16 digital, 0.5 A each, total current 4 A
2 analog 4-20 mA
Interfaces RS 485 interface
(2nd interface optional)
Interface functionality MPI
PROFIBUS DP (optional)
Integrated RAM 64 KBytes
Storage memory plug-in Micro Memory Card, 128 KBytes
Backup ensured by Micro Memory Card (MMC), no
battery needed.
Configuration software STEP 7 from V 5.2 + SP 1 + HSP
Enclosure IP20
There is no protection provided against
water inrush!
2.5.2 Control cabinet

Connection voltage 115/230 V AC (± 10 %)
Frequency 50 to 60 Hz (± 5 %)
Control voltage 24 V DC
Ambient temperature 0 to 45 °C (32 to 113 °F)
It is mandatory to indicate if higher ambient
temperatures apply.
Housing, 1-part/compact design Painted sheet steel, RAL 7035
(special designs possible)
Enclosure IP 54

8555-9001-200 / 0309 33
(in case of appropriate assembly as speci-

fied under "Installation and connection")
Standard dimensions 1000 x 1200 x 300 mm
(width x height x depth)
Weight design-dependent
Cable entry from below / from beside
ambience conditions 3C2 according to EN 60721-3-3
Electromagnetic compatibility A according to EN 55011
Climatic conditions checked against IEC 60068-2-1, IEC

60068-2.2
Operation:
0 - 55 °C (32 - 131 °F) for vertical installa-
tion
Storage:
-20 °C to +70 °C (-4 to 158 °F)
Humidity:
5 – 95 % at 25 °C (77 °F)
Mechanical ambient conditions Vibrations during operation:
checked against 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)
/
– LRS (Lloyds Register of Shipping)
classification societies
– DNV (Det Norske Veritas)
– BV (Bureau Veritas)
– ABS (American Bureau of Shipping)
– RINA (Registro Italiano Navale)
– NK (Nippon Kaigi Kyokai)

34 8555-9001-200 / 0309
2.5.3 Digital inputs/outputs (DI/DO)
ATTENTION!
The following digital input/output chart comprises the entire standard scope of
supply.
• Pay attention to project-related configurations!
Refer to the circuit diagram in the electrical documentation in the control cabi-
net.
Digital inputs (DI . . .)
Connection Function
DI 0.0 Separator - Operation

DI 0.1 Separator Fault
DI 0.2 Spare
DI 0.3 Speed monitoring separator
DI 0.4 Spare
DI 0.5 Water discharge (only …-0136-… or …-0196-…)
DI 0.6 Spare
DI 0.7 LSHH – solids vessel
DI 1.0 Feed pump - Operation

DI 1.1 Feed pump - Fault
DI 1.2 Solids pump - Operation
DI 1.3 Solids pump - Fault
DI 1.4 LSH Solids vessel, for pump start
DI 1.5 LSL Solids vessel, for pump stop
DI 1.6 Separator Vibro Stage 1
DI 1.7 Separator Vibro Stage 2
DI 2.0 Spare
DI 2.1 Spare
DI 2.2 Spare
DI 2.3 Spare
DI 2.4 Spare
DI 2.5 Spare
DI 2.6 Spare
DI 2.7 Emergency-Off

8555-9001-200 / 0309 35
Digital outputs (DO . . .)
Connection Function
DO 0.0 Separator - Feed valve

DO 0.1 Displacement- and filling-water valve
DO 0.2 Operating water valve
DO 0.3 Heater release
DO 0.4 Circulation valve (only …-0136-… or …-0196-…)
DO 0.5 Water discharge valve (only …-0136-… or …-0196-…)
DO 0.6 Lamp test (option)
DO 0.7 Collective alarm
DO 1.0 Separator ON/OFF

DO 1.1 Feed pump ON/OFF
DO 1.2 Valve pneumatic solids pump
DO 1.3 Surge tank alarm
DO 1.4 TAH - Temperature alarm max.
DO 1.5 TAL - Temperature alarm min.
DO 1.6 PID - Control valve OPEN
DO 1.7 PID - Control valve CLOSE

36 8555-9001-200 / 0309
2.5.4 Analog inputs and outputs (AI/AO) - 4 – 20 mA
Analog inputs (AI . .)
Connection Function
AI 0.0 Motor current and ejection monitoring

AI 0.1 Clean oil discharge
AI 0.2 SMS transmitter / water discharge
AI 0.3 PID controller for product temperature
AI-AIR PT100 Product temperature
Analog outputs (AO . .)
Connection Function
AO 0-I Motor current

AO 1-I Temperature

8555-9001-200 / 0309 37
2.6 Configuration
The construction can vary depending on the delivery scope.
The controls are fitted in the door of the control cabinet ready for connection.
ATTENTION!
• Refer to the order-specific drawing in the electrical documentation.
2.6.1 Frontal view control cabinet
Fig. 21 Frontal view control cabinet (example)
1 Lock
2 Control cabinet E40
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

38 8555-9001-200 / 0309
2.6.2 Inner view control cabinet
Fig. 22 Inner view control cabinet (example)
1 Door lock (180°)

2 CPU / expansion modules
3 Power supply unit (24 V DC)
4 Switch amplifier (option)
5 Interface relay
6 Duct for wiring
7 Terminal block
8 Motor starter
9 Contactor
10 Motor protection switch
11 Safety cutout
12 Control transformer (Option)
2.6.3 Special versions

Special versions differing from the one described in this manual are available:
• The housing
– can have other dimensions.
– can be made of stainless steel.
• Individual components of the control can be integrated in a compact control
cabinet or in a central control.

8555-9001-200 / 0309 39
3 Operation
3.1 Getting to know the operating elements ................................................ 40

3.1.1 Softkeys and their symbols .................................................................... 41
3.1.2 System keys (Touch) ............................................................................. 43
3.1.3 Edittext, numerical values or fields ........................................................ 45
3.2 Password protection .............................................................................. 46
3.3 Switch oncontrol unit .............................................................................. 46
3.3.1 Overview of the menus .......................................................................... 48
3.3.2 Main menu (HOME) ............................................................................... 49
3.4 Process diagrams .................................................................................. 50
3.4.1 Process overview ................................................................................... 50
3.4.2 Detailed views ........................................................................................ 52
3.4.3 Separator control area ........................................................................... 53
3.4.4 Graphic representation for current and speed ....................................... 56
3.4.5 UNITROL Range ................................................................................... 57
3.4.6 Light sequence area .............................................................................. 58
3.4.7 Sludge tank range .................................................................................. 59
3.4.8 Heater range .......................................................................................... 60
3.4.9 Symbols in all process pages ................................................................ 62
3.5 Temperaturecontroller ........................................................................... 63
3.5.1 Controller curve (graphic representation) .............................................. 65
3.6 Commissioning data and service addresses ......................................... 66
3.6.1 Commissioning data .............................................................................. 66
3.6.2 Service addresses worldwide ................................................................ 67
3.6.3 Local date and time adjustment ............................................................. 68
3.7 Timer ...................................................................................................... 70
3.7.1 Modify time value (example) .................................................................. 71
3.7.2 Timer without password (user times) ..................................................... 72
3.7.1 Timer with Password ............................................................................. 73
3.7.2 Counter .................................................................................................. 74
3.8 Digital/analog inputs/outputs.................................................................. 76
3.8.1 Analog Input 1 - AI-0.0 ......................................................................... 77
3.8.2 Analog input 2 - AI-0.1 ......................................................................... 78
3.8.3 Analog input 3 - AI-0.2 ......................................................................... 79
3.8.4 Analog input 4 - AI-03 .......................................................................... 80
3.8.5 Analog input 5 - AI-AIR (P T100 - Dire c t in p u t) .................................. 81
3.8.6 Analog outputs ....................................................................................... 82
3.8.7 Status of the digital inputs/outputs ......................................................... 83
3.9 Operating hours and settings................................................................. 85
3.9.1 Settings .................................................................................................. 86
3.10 Separator faults ..................................................................................... 88
3.10.1 Fault messages ..................................................................................... 88
3.10.2 Displaying queued fault messages ........................................................ 89
3.10.3 Displaying the fault message buffer ...................................................... 90
3.10.4 Register alarm messages ...................................................................... 91
3.10.5 Status and fault indication .................................................................. 94
3.11 SwitchMicro Memory Card (MMC) ........................................................ 95
3.12 CPU Master Reset ................................................................................. 96
3.13 LoadNew Visualisation .......................................................................... 97

40 8555-9001-200 / 0309
3.1 Getting to know the operating elements
3
1
Fig. 23 Control unit
The control unit (operator panel) is built into the door of the control cabinet. The
operating interface consists of:
1 Softkeys
2 Graphic display
3 ACK (acknowledge fault)
Note: The <ACK> key is used to acknowledge the error messages currently queued,
and all messages of an acknowledgement group (collective acknowledge-
ments).
– The fault is not remedied automatically.
– The LED (<ACK>key) flashes for as long a fault is present.

8555-9001-200 / 0309 41
3.1.1 Softkeys and their symbols

The softkeys have local functions: The functions that can be triggered depend
on the picture currently shown in the display and are marked by a symbol on the
display or above the key.
Since it is a touch panel, the function can either be triggered by touching the
symbol or the allocated key.
The following symbols always have the same significance.
Key Key designation Description
Calls up the main menu Call-up of the “main menu” page
Process overview diagram Call-up of separator process overview diagram
Commissioning data and ser- Call-up of commissioning data and service addresses
vice addresses
Timer pages Call-up of timer page
Analogue and digital inputs / Calls up the process display of all the inputs/outputs
outputs
Operating hours and settings Calls up the menu “operating hours and settings”
Error message overview Calls up all current and stored error messages
Process sequence OFF Stopping the process sequence
Process sequence ON Start process sequence
Water monitoring system Call-up of water monitoring process diagram
Light discharge Call-up of monitoring process diagram "Light Discharge"
Sludge tank Call up of monitoring process diagram "Solids/Sludge tank"
Controller data Call-up of monitoring process diagram "Controller Page"
Separator speed and current Call-up of speed and current setting process diagram
settings
Previous page Exits page to previous page
Page jump right Exits the page to the right
Page jump left Exits the page to the left
Language switching Changes the language

42 8555-9001-200 / 0309
Windows CE Calls up the operating system “Windows CE”
Touch screen calibration Starts the touch screen calibration
Contrast + Changes the contrast:

Increases the contrast
Contrast - Changes the contrast:
Reduces the contrast
Lamp test LEDs of the operator panel and local pilot lamps of the control
cabinets are checked for functionality.
Configuration page Call-up of configuration page
Machine simulation pages Call-up of machine simulation pages: All inputs and outputs can
be independently simulated:
Saving process data The parameters currently set are saved on the Micro Memory
Card (MMC).
A message from the memory is displayed during the saving
process.
Loading process data The values are read out from the MMC. All previously saved
settings are restored. A message is displayed during the rea-
ding process.
Help text Calls up the help text
Sludge pump inching The sludge pump is on as long as the key is pressed:
Automatic and manual opera- Set the temperature controller to automatic or manual opera-
tion tion.
Closing the steam-regulating Close the steam-regulating valve in manual operation by press-
valve ing this key.
Open the steam-regulating Open the steam-regulating valve in manual operation by press-
valve ing this key.
Controller curves Call up graphic representation of temperature controller curve
Reducing the time intervals Reducing the time intervals in the temperature, current or speed
curve
Increasing the time intervals Increasing the time intervals in the temperature, current or
speed curve

8555-9001-200 / 0309 43
3.1.2 System keys (Touch)

The numeric entry, e.g. for password entries or setpoint changes (see section
3.7.1) occurs by means of the system keys.
The system keys appear only when touching the corresponding field.
System keys 1..-

Numeric keypad
(displayed only for setpoint change)
Fig. 24
System keys 2..-

Alphanumeric keypad
(displayed for changing text and/or
setpoint)
Fig. 25
Arrow right/left If a menu has input boxes the arrow keys

are used to navigate from one box to
another.
ESC (cancel) With this key, entries can be undone as

long as they have not been confirmed
with the <ENTER> key.
ENTER This key is used to confirm and terminate

entries.
(accept)
Switch-over This key is used to switch between upper

case and lower case letters and vice
(upper case/lower
versa.
case letters)
Delete character Pressing this key deletes individual cha-

racters.

44 8555-9001-200 / 0309
System keys 3
(displayed in case of error
messages)
Fig. 26 Fault messages (example)
Show help text A help text with information on the mes-

sage displayed opens.
Fault This key is used to acknowledge the
acknowledgement currently displayed error messages (col-
lective acknowledgements).
The fault is not automatically remedied.

8555-9001-200 / 0309 45
3.1.3 Edittext, numerical values or fields
Fig. 27 Timer overview with password (example)
Editing texts, numerical values or fields is always done in the same way.
Ed itin g a n um e ric a l va lu e (example)

– Modifyvalue from5 to 10.
Entering the value

Key Description
• Touch the field to be changed with your finger.

– A key field appears on the panel with the entry field
to be changed.
• Enter the new value 10 using the numeric keys.
• Confirm the entry with <ENTER>.
Correcting, deleting an entry

Key Description
• Position the cursor inside the entry field in front of the

desired figure.
• The figure (e.g. “1”) can now be inserted or
• deleted.
• Confirm the entry with <ENTER> or
• cancel the entry with <ESC>.

46 8555-9001-200 / 0309
3.2 Password protection

Certain entries and functions require prior entry of a user and password.
When selecting “company-specific basic settings”, password level 9, the user is
prompted to enter the user and the corresponding password.
Note: The user name and the password can be obtained from Westfalia Separator
Systems GmbH.
IMPORTANT:
When the password is entered incorrectly three times
– the user is blocked,
– no more password-protected entries can be made!
– Inform GEA Westfalia Separator Systems GmbH.
Fig. 28 Registration
If no operation occurs for two minutes, the program returns to entry level 0 (Lo-
gout). For further processing, the password has to be re-entered.
ATTENTION!
Then, however, the called-up menu is not protected. This means that even un-
authorized persons can carry out changes in this menu.
3.3 Switch oncontrol unit

When the control unit is switched on, an operating system test is carried out for
the CPU and the control element (OP). Required data is loaded from the Micro
Memory Card (MMC).
IMPORTANT:
Do not press any key when the control system is starting!
Pressing a key results in an abnormal system end.
Wait until the control system has run up after max. 50 seconds and the main
menu is displayed.

8555-9001-200 / 0309 47
Fig. 29 Main menu (example)
The date and time are displayed in the upper line, the control type is displayed
in the middle.
The individual sub-menus can be called up from the main menu (see section
3.3.2).
Note: To avoid long run-up times, the control unit should be under voltage even when
the separator unit is not used.

48 8555-9001-200 / 0309
3.3.1 Overview of the menus
Fig. 30 Main and sub-menus (example)
1 Main menu (HOME) 3.3.2

2 Selection of process diagrams 3.4
3 Commissioning data and service addresses 3.6
4 Timer page 3.7
5 Service page “digital/analogue inputs / outputs” 3.8
6 Operating hours and service 3.9
7 Fault message and operating message memory 3.10.3

8555-9001-200 / 0309 49
3.3.2 Main menu (HOME)

The main menu is called up
• after switching on the control (see sec.3.3) or
• after pressing the key “HOME”.
Fig. 31 Main menu (example)
The date and time are displayed in the upper area of the main menu. They can
only be set on the commissioning data page, e.g. to the desired local time (see
sec. 3.6.3).
The following sub-menus are called up from the main menu by pressing the cor-
responding symbol or the allocated key (softkeys).
Key Key designation Section
Calling up the process diagrams 3.4
Calls up the commissioning data and service ad- 3.6

dresses
Calls up the timer page 3.7
Calls up the service page „digital/analogue in- 3.8

puts/outputs“
Calls up the menu “operating hours and settings” 3.9
Calls up the fault message and operating mes- 3.10.3

sage memory

50 8555-9001-200 / 0309
3.4 Process diagrams
The process diagrams are called up from the main menu by touching
the symbol “process diagrams” or pressing the allocated key.
The sub-menu “process diagrams” consists of a process overview and five de-
tailed views.
ATTENTION!
Refer to the order-specific electrical documentation in the control cabinet!
.
3.4.1 Process overview

In this sub-menu, the complete separator with the allocated valves, pumps and
process display is represented.
Fig. 32 Process overview (example)
Display/key Meaning
Display and status (ON/OFF/FAULT) of product feed pump
Current value of product feed temperature (°C)
Display and status of product feed valve
Current pressure (bar) of clean oil discharge
Display and status of fill, displacement water and discharge

valve

8555-9001-200 / 0309 51
Display/key Meaning
Process display
Upper menu line

– The current program status is displayed.
Off (Aus)
Separator is not switched on.
Run-up (Hochlauf)
The separator is in its start-up phase; no process start is poss-
ible.
Ready (betriebsbereit)
The separator is at operating speed; the separating process
can begin.
Separation (Separieren)
The separator is in process; the clean oil feed is open, or the
ejection program is running.
PTC alarm (PTC-Alarm)
The motor protection device has responded; the separator
was disconnected from the mains and the product feed valve
closed.
Lower menu line

– The current process status is displayed.
– The current time to process status is displayed.
Recirculation (Kreislaufbetrieb)
The product feed valve is in recirculation mode. The separator
is in its run-up or fault mode, or the process has not been
launched.
Wait (Warten)
The separating process has been launched.
Displacement (Verdrängen)
The bowl contents are displaced without loss by opening the
displacement water valve.
Wait after displacement (Warten nach Verdrängen)
A waiting period runs after displacement.
Total ejection (Totalentleeren)
The sludge space of the bowl is emptied by actuating the op-
erating-water valve.
Speed recovery (Drehzahlerholung)
The speed drop occurring during ejection is compensated.
Filling (Füllen)
The filling operation establishes the required water seal in the
-96- version of VARIZONE and UNITROL separators.
Wait after filling (Warten nach Füllen)
A waiting period runs after the filling process.
Feed valve open (Zulaufventil offen)
The separating process is activated.
Sensor check (Sensortest)
The individual sensors are tested.
Display of current value (A) and/or speed value (R/min)
Process sequence OFF

52 8555-9001-200 / 0309
Display/key Meaning
Process sequence ON
3.4.2 Detailed views
Key Range Section
Separator, speed and current settings 3.4.3
Water monitoring display 3.4.5
Display light phase discharge 3.4.6
Display sludge tank 0
Display heater 3.4.8

8555-9001-200 / 0309 53
3.4.3 Separator control area
The separator control area is called up from the process overview by

touching the symbol “Sep Control” or pressing the allocated key.
Depending on the type of monitoring selected, either Current or Speed
Monitoring are displayed.
ATTENTION!
4
1
2
5
Fig. 33 Current/speed monitoring (example)
The graph displays the motor current and present bowl speed.
The relevant parameters are preset at the factory. For a precise description of
the values that have or shall be set, see separate instructions "Settings and
Faults".
Positi-
Meaning
on
1 Power indicator
2 Speed indicator
3 Speed monitoring settings
4 Bowl monitoring settings
5 Ejection monitoring settings
Display/key Meaning
Speed max. Highest threshold value for bowl speed monitoring

(Drehzahl max.)
Speed min. Lowest threshold value for bowl speed monitoring
(Drehzahl min.)

54 8555-9001-200 / 0309
Display/key Meaning
Offset bowl monitoring (Aufrechnung für Trommelüberwachung)

Offset motor current Offset motor current
(Offset-Motorstrom)
Offset speed Offset speed
(Offset-Drehzahl)
Offset ejection monitoring (Aufrechnung für Entleerungsüberwachung)
Offset motor current Offset motor current
(Offset-Motorstrom)
Offset speed Offset speed
(Offset-Drehzahl)
Call-up of characteristic temperature curve
Exits page to previous page
Editing occurs as described in the chapter 3.1.3 "Edit Texts, Numerical values or
Fields".
Function
Offset Bowl Monitoring: with motor current

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 controlled as follows:
– 3 seconds before closing water impulse injection, the present operating
current of the separator is measured and saved;
– 3 seconds after closing water injection, the measurement is repeated, and
the value is compared with the previous current value.
With a deviation > 1 , a corresponding alarm sounds; the separating process
is not interrupted.
Offset Bowl Monitoring: with speed
For bowl monitoring, the cyclical closing water impulse for the bowl hydraulics
is monitored, i.e.: if the closing water rate is too high, the bowl is opened,
which causes a speed drop and is controlled as follows:
- 3 seconds before closing water impulse injection, the present speed of the
separator is measured and saved.
- 3 seconds after closing water injection, the measurement is repeated, and
the value is compared with the previous speed.
With a deviation > 100 R/min , a corresponding alarm sounds; the separating
process is not interrupted.

8555-9001-200 / 0309 55
Function
Offset Ejection monitoring: with motor current

• In separation mode, initiate a total ejection with the <Process ON> key, and
• observe the ejection current in the corresponding display.
The ejection current is normally higher than the rated current in the sepa-
rating program.
• Enter the difference between ejection current and separating current (e.g.
2.0 A) as offset value.
ATTENTION!
The ejection monitoring will be out of service if 0.0 A has been
entered as offset value!
However, this should only occur in exceptional cases (e.g., with
mechanical faults).
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 28, the current has
to increase by this value. The offset value is preset on this page.
Example:
– The present operating current before opening the operating water valve is
10 A.
– Following ejection via the operating water valve, the current generally rises
to 13 A.
– An offset value of 2 A is entered as monitoring value.
10 A operating current + 2 A offset value = 12 A monitoring current
This total must be exceeded during ejection (e.g., 13 A).
Offset Ejection monitoring: with speed
Just before an ejection, the speed is read off and the differential value added.
After the ejection, within the time setting of timer 27, the speed has to de-
crease by this value.
• In separation mode, initiate a total ejection with the <Process ON> key, and
• observe the ejection speed in the corresponding display.
As a rule, the ejection speed is lower than the speed in the separator pro-
gram.
• Enter the difference between the ejection speed and the speed in the sepa-
rator program as offset value.
ATTENTION!
The ejection monitoring will be out of service if 0 R/min has been
entered as offset value. However, this should only occur in excep-
tional cases (e.g., with mechanical faults).
Example:
(Speed in separator program: 10,000 R/min - ejection speed: 9,700 R/min) -
10 % = differential speed: 270 R/min

56 8555-9001-200 / 0309
3.4.4 Graphic representation for current and speed

In the following representation the bowl speed and absolute peak values are
recorded. These are graphic representations in the form of curves.
Fig. 34 Speed (example)
Display/key Meaning
Speed recording Speed measurement

Peak Peak value
Actual value current value
Alarm value max. Alarm value max.
Alarm value min. Alarm value min.
Reducing the time intervals in the current or speed

curve
Increasing the time intervals in the current or speed
curve
Exits page to previous page
Call-up of graphic representation current/speed

8555-9001-200 / 0309 57
3.4.5 UNITROL Range
The Unitrol range is called up from the process overview by touching

the symbol “UNITROL” or pressing the allocated key.
ATTENTION!
Fig. 35 UNITROL Range (example)
Position Meaning
V6 Water discharge valve

2 Water sensor (WSM)
3 Status SMS Pressure Switch
V5 Circuit valve
Display/key Meaning
1.0 bar Current status of SMS pressure in bar.
15 Circulation valve shut (current status in seconds)

16 Circulation valve open (current status in seconds)
Open circulation valve V5 by pressing key.
Open circulation valve V6 by pressing key.

58 8555-9001-200 / 0309
3.4.6 Light sequence area
Call-up of the area for discharge of the light liquid occurs from process
overview by touching the "Light discharge" symbol or the assigned
key.
ATTENTION!
Fig. 36 Light liquid discharge (example)
Position Meaning
1 Status PSH pressure switch

8555-9001-200 / 0309 59
3.4.7 Sludge tank range
The sludge tank range is called up from the process overview by

touching the symbol “Sludge Tank Range” or pressing the allocated
key.
ATTENTION!
2
3
Fig. 37 Sludge tank range (example)
Position Meaning
1 Time status display (current status in seconds)

24: Sludge pump delay (Feststoffpumpennachlaufzeit)
40: Sludge pump operation (Feststoffpumpenlaufzeit)
41: Sludge pump break (Feststoffpumpenpausenzeit)
2 Sludge pump
3 Status display for sludge tank alarm
4 Sludge tank filling level sensor
Display/key Meaning
LSHH Alarm The lettering flashes in case of sludge tank overflow.

(LSHH-Alarm)
Sludge pump inching ON

60 8555-9001-200 / 0309
3.4.8 Heater range
The heater range is called up from the process overview by touching

the symbol “heater range” or pressing the allocated key.
ATTENTION!
Fig. 38 Module outlet (example)
Display/key Meaning
Control valve
Control valve directional sign
Heat exchanger
Temperature actual value (°C)
Switch between automatic and manual mode
Operating mode
Here, the operating mode of the temperature controller can
be selected:
• Automatic operation
• Manual operation
The control function is basically locked with the product
feed pump operating signal; with pump "Off", the motor
control valve is automatically closed.
This key is only active in controller manual mode.
This key is used to decrease the control value of the con-
troller.
This key is only active in controller manual mode.
This key is used to increase the control value of the con-
troller.

8555-9001-200 / 0309 61
Display/key Meaning
Calls up the controller setting

62 8555-9001-200 / 0309
3.4.9 Symbols in all process pages
Symbol Description
Product feed pump

Motor OFF
(Display colour: grey)
Motor ON
(Display colour: green)
Motor malfunction
(Display colour: red)
Run-up and post-run

(Display colour: yellow)
Input and output status

Signal present
Signal not present
Pipes
No product (empty pipe)
Product
(Display colour: black)
Valves
Valve closed
Valve open
(Display colour: blue)
3/2 valves
Valve position 1
Valve position 2
Pressure pickups
Outside the limit value
Inside the limit value


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Symbol Description
Sludge pump
Sludge pump OFF
Sludge pump ON
Sludge pump post-run

Sludge pump malfunction

(Display colour: red, flashing)
3.5 Temperaturecontroller
The temperature controller is called up from the heater range by touch-

ing the symbol “arrow right” or pressing the allocated key (s. sec. 3.4)
In this sub-menu, a PI software controller with outputs for a motor adjustment is

represented, along with a 4-20 mA analog input for product temperature control.
For this, a PT100 signal from the unit must be converted into a 4-20 mA signal
via a measuring transducer.
Editing is described in section3.1.3.
The controller can be operated both in automatic and manual mode.
Setting parameters are preset at the factory.
Fig. 39 Temperature controller (example)

64 8555-9001-200 / 0309
Display/keys Meaning
Setpoint limit Measuring range

Adjusting range of the employed PT100 sensor.
Setpoint Set temperature
Setting for the desired clean oil temperature.
Setpoint Max Threshold value max.
Highest limit value for separating-temperature monitoring
Setpoint Min Threshold value min.
Lowest limit value for separating temperature monitoring
Offset Temp. Offset Temperature – Warning
Warning
Highest/lowest threshold value for separating temperature
warning
Control ampli- Controller amplification (low = …; high = . ..)
fication
Influences the time to reach the set temperature.
(low = slower;
high = faster)
Call-up graphic representation of temperature controller

curve

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3.5.1 Controller curve (graphic representation)
In this menu, the set and actual values of the controller are
represented graphically in the form of a curve.
The dashed line represents the setpoint, the drawn through line
represents the actual value.
Fig. 40 Temperature pattern (example)
Display/key Meaning
Temperature
recording
(temperature
recording)
Peak
(Spitzenwert)
Actual value
(aktueller
Wert)
Alarmvalue
min/max
(Alarmwert
min./max.)
PI Setpoint
(PI-Sollwert)
Increasing the time intervals
Reducing the time intervals
Switches back to the controller screen..

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3.6 Commissioning data and service addresses
In the menu “commissioning data and service addresses”, the data

entered by the Westfalia service personnel during commissioning and
the service addresses of Westfaliia Separator Systems can be viewed
worldwide.
3.6.1 Commissioning data
The commissioning data are called up from the main menu by touch-
ing the symbol “commissioning data and service addresses” or press-
ing the allocated key.
Fig. 41 Commissioning data (example)
The local date and time adjustment is carried out as described in section3.6.3.
Editing the serial number and commissioning date is described in section3.1.3
.
Display/key Meaning
Date Display current date

(Date)
Time Display current time
(Time)
Number of centrifuge Entry of separator serial number
(separator serial num-
ber)
Commissioning date Entry of the commissioning date
(commissioning date)
Program number Display of the software number
(Program number)
The final 3 digits indicate the version.
Unit type Type of the control unit “E40”
(Type of control unit)

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Display/key Meaning
Part No. Part number of the control unit PLC (complete)

(Part-No.)
Network address Display of the network address of the control
(network address)
Jump back to main menu
Jump to menu “service addresses worldwide”
3.6.2 Service addresses worldwide
Service addresses worldwide are called up from the main menu by

touching the symbol “commissioning data and service addresses” or
pressing the allocated key.
Fig. 42 Service addresses (example)
Key Meaning
Jump to menu “commissioning data”

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3.6.3 Local date and time adjustment
Setting the date (11.01.08)
11.01.08 Date format German (DD.MM.YY)
01/11/08 Date format English (MM.DD.YY)
Key Description
• Touch the date entry field with your finger.

– A key field appears on the panel with the entry
field to be changed.
• Enter the first two digits of the date with the corres-
ponding numeric keys.
• Press the period key in the numeric keypad.
• Enter the middle two digits of the date with the nu-
meric keys.
• Press the period key in the numeric keypad.
• Enter the last two digits of the date with the numeric
keys.
• Confirm the entry with <ENTER>.

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Setting the time (11:56:40)
11:56:40 Time format – international (HH:MM:SS)
Key Description
• Touch the time entry field with your finger.

• Enter the first two digits of the time (HH) with the
corresponding numeric keys.
• Press the colon key in the numeric keypad.
• Enter the middle two digits of the time (MM) with the
• Press the colon key in the numeric keypad.
• Enter the last two digits of the time (SS) with the
• Confirm the entries with <ENTER>.

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3.7 Timer
The timers are called up from the main menu by touching the symbol
“Timer”” or pressing the allocated key.
You can scroll between the different screens in this menu.
IMPORTANT:
The following pages show the standard timers. The number and display of the
timers depend on the configuration of the separator.
Observe order-specific timer lists in instructions "Settings and Faults"!
Fig. 43 Timer list with password - Page 1 (example)
All timers run from setpoint to 0. The setpoint can be edited and modified in the
3-D highlighted column (s. sec. 3.7.1).
ATTENTION!
Modified setpoints become active after timer run-down.
Possible time units

The time unit of the timer is displayed in seconds (s) at right.
Call-up of additional functions
Key Meaning
Switches to the main menu.
Switches to the previous timer screen.
Switches to the next timer screen.

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3.7.1 Modify time value (example)

– Modify the value for „S ta rt S e p a ra to r“ from 240 s to 200 s.
Key Description
Entering the value
• Touch the field to be modified with your finger.

• Enter the new value 200 using the numeric keys.
• Confirm the entry with ENTER.

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3.7.2 Timer without password (user times)
Timers without password are called up from the main menu by touching
the symbol “Timer”” or pressing the allocated key.
Fig. 45 Timer without password (example)
The actual value (current) is displayed for each timer.

The setpoint (preselection) and the associated unit are displayed and can be
edited.
Editing of timers occurs as described in the chapter 3.1.3 "Texts, Numerical val-
ues, Fields".
Actual
Timer Preset
Meaning (Actual
No. (Setpoint)
value)
20 Separation (Separieren) 7200 s
Auto calculation timer (automatischer Kalkulationstimer)
01 Displacement (Verdrängen) 12
Auto setpoint calculate 10
(Auto times calculate)
02 Filling (Füllen)
Auto setpoint calculate 10
(Auto times calculated)
IMPORTANT!
When switching into serial operation, set the timer's bridging time to a minimum
value of approx. 70 seconds. This prevents a PAL alarm on the clean oil dis-
charge side of the second separator.
When restarting the separator and at the corresponding speed, Timer 10 can
momentarily be set on 0 in order to shorten the renewed starting time. It is im-
perative to subsequently re-enter the factory setting value.

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3.7.1 Timer with Password
The timers with password are called up from the main menu by touch-
ing the symbol “Timer”” or pressing the allocated key.
The timers can only be modified or adjusted following entry of the password.
ATTENTION!
Correct timer setting is crucial to trouble-free separator operation. When in
doubt, consult with GEA Westfalia Separator.
The actual value (current) is displayed for each timer.
The setpoint (preselection) and the associated unit are displayed and can be
edited.
Editing of timers occurs as described in the chapter 3.1.3 "Texts, Numerical val-
ues, Fields".

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3.7.2 Counter
The timer overview is called up from the main menu by touching the
symbol “timer”” or pressing the allocated key.
The counter page is reached by repeatedly touching the symbol.
Fig. 47 Counter page (example)
Flu s h e je c tio n
Actual
Counter Preset
Meaning (Actual
No. (Setpoint)
value)
01 Flushing (Spülentleeren) 10
The number of total ejections to be performed until an automatic flush ejection is

triggered is entered in the input field (setpoint). When operating without flush
ejection, set the counter to “0“.
Upon each total ejection performed, the actual value is reduced by “one”. When
the “0” value is reached, the next total ejection will be followed by the desired
flush ejection.
No te : Correct timer setting is crucial to trouble-free separator operation. When in

doubt, consult with Westfalia Separator.
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.
P a rtial a n d tota l e je c tion

Actual
Counter Preset
Meaning (Actual
No. (Setpoint)
value)
02 Partial and total ejection 8

8555-9001-200 / 0309 75
When modifying the operating-water system, partial-ejection programs can be

run on the different separator types as well, if desired.
The number of partial ejections to be performed until a double total ejection is
triggered is entered in the input field (setpoint).
Upon each partial ejection performed, the actual value is reduced by “one”.
When the “0” value is reached, the next partial ejection will be followed by the
desired double total ejection.
No te : The partial ejection mode is preset at the factory!
Fillin g in S MS m o d e
Actual
Counter Preset
Meaning (Actual
No. (Setpoint)
value)
03 SMS Filling 3
For single-stage LO separation in WMS/SMS mode, a system check of the SMS

function is performed by repeated filling-water injection. The number of fillings is
preselected on counter C3. The factory setting should only be altered for testing
purposes.
The number of filling-water injections to be performed until system pressure
builds up is entered in the input field (setpoint). The system pressure is recorded
by the SMS sensor, and (if applicable) operation is switched back from SMS to
WMS.
If no pressure is detected after the third filling-water injection, the ejection pro-
gram is triggered.
Sens or check
Actual
Counter Preset
Meaning (Actual
No. (Setpoint)
value)
04 Here the number of ejection intervals is 5
defined, after an automatic sensor
check .

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0.5 % v/v wa ter

Actual
Counter Preset
Meaning (Actual
No. (Setpoint)
value)
05 In the separating program, with dis- 3
charge valve closed and timer 47
started, the pressure in the bypass line
is registered and reduced by one.
If, within the separating interval, the “0“
value is reached, the alarm “Caution,
water content > 0.5%” appears.
3.8 Digital/analog inputs/outputs
The digital/analogue inputs/outputs are called up from the main menu

by touching the symbol “inputs/outputs” or pressing the allocated key.
You can switch between the individual screens in the menu.
Note: All process variables can be transmitted to an overriding control system as a

420 mA signal. An amplifier with galvanic isolation must be available for the
transmission.
Calling up further functions
Key Meaning
Switches to the previous input/output screen.
Switches to the next input/output screen.
Set threshold values for parameters

Editing is described in section 3.1.3.
ATTENTION!
The displays and the number of detailed views can change depending on the
configuration.

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3.8.1 Analog Input 1 - AI-0.0
Fig. 48 Page 1 (example)
Function Terminal
Sep.-Motor current (Separator Motor Current): AI -0.0

Due to the different motor ratings, the transmission ratio of the
current transformer can be adjusted, when using external mo-
tor starters, to ensure that the display of the control unit indi-
cates the correct motor current of the separator. The desired
transformer ratio can be selected from the following options:
– 10/1 A
– 25/1 A
– 50/1 A
– 100/1 A
Measuring principle:
The transducer signal of max. 1 A on the transformer's sec-
ondary side is led along a twin-core cable to a measuring
transducer in the control unit's housing and converted to a 4-
20-mA signal, which is switched to the control unit as an ana-
log input and is then visualised in the process display. The
signal
– continuously displays the present separator current value,
and
– is used as a parameter for the ejection monitoring.

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3.8.2 Analog input 2 - AI-0.1
Function Terminal
Clean oil outlet (Reinölablauf): AI -0.1

Current clean oil display, determined from pressure transmit-
ters located in the pipe system.
PAL Pressure (PAL-Druck):
Lowest limit value for monitoring the clean oil discharge pres-
sure
PAH Pressure (PAH-Druck):
Highest limit value for monitoring the clean oil discharge pres-
sure

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3.8.3 Analog input 3 - AI-0.2
Function Terminal
Current SMS pressure (SMS-Druck aktuell): AI -0.2

Current SMS pressure display, determined from pressure
transmitters located in the pipe system.
SMS Pressure (SMS-Druck):
Highest and lowest limit for SMS pressure monitoring

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3.8.4 Analog input 4 - AI-03
Function
PI Controller (PI-Regler):
The control-unit software is provided with a PI controller which, in combination
with optional hardware components, allows control of the clean-oil tempera-
ture.
Adjustment of the control mode and/or adaptation of the controller to local
conditions is described in chapter 3.5Temperature Controller.
Note: When using the integrated PI controller, this analog input is assigned to clean-
oil temperature control. It is supplied with a 4-20-mA signal via dual-purpose
thermometer and only indicates the current temperature in this display.
• For additional information, see Chapter 3.5 Temperature Controller.
Temperature monitoring and control are independently projected over two
channels, according to classification rules.

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3.8.5 Analog input 5 - AI-AIR (P T100 - Dire c t in p ut)
Function
Feed temperature PT100 (Clean oil temperature PT100):

Current clean oil feed temperature display, determined by PT100 located in
the pipe system.
Compensation (Kompensation):
Coeefficient entry occurs to compensate measurement differences through
line loss. For this, enter the temperature difference value in degrees Celsius
(°C), as yielded by local on-site measurement and indicated as a temperature
value in the display.
Entry of a coefficient does not apply in the case of 3- or 4-conductor connec-
tions.
Setpoint Min (Setpoint-Min):
Lowest limit value for separating temperature monitoring
If min. separating temperature is exceeded, launch of separating
program is not possible.
– The process cannot be initiated.
Setpoint Max (Setpoint-Max):
Highest limit value for separating-temperature monitoring
Offset Temp. Warning (Offset Temperatur-Warnung):
Highest/lowest threshold value before temperature alarm

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3.8.6 Analog outputs
Analog
Function Signal
output
Sep.motor current (option)

AO 0.0 4 – 20 mA
(Separator Motor Current (Option))
Feed temperature (option)
AO 0.1 4 – 20 mA
(Clean Oil Temperatur (option))
Note: Process variables such as separate motor current and clean oil temperature can
be transmitted to an overriding control system as a 420 mA signal.
• An amplifier with galvanic isolation must be available for the transmission.

8555-9001-200 / 0309 83
3.8.7 Status of the digital inputs/outputs
In this menu, the current status of the digital inputs and outputs can be
viewed.
(standard allocation, see section2.5.3.)
ATTENTION!
The following digital input/output chart comprises the entire standard scope of
supply.
• Pay attention to project-related configurations!
Refer to the circuit diagram in the electrical documentation in the control cabi-
net.
Fig. 54 Digital inputs (example)
Fig. 55 Digital outputs (example)

84 8555-9001-200 / 0309
Softkeys
Key Meaning
Switches to the previous input/output screen.
Switches to the next input/output screen.
Status Definition
Status Meaning
Input signal 24 V DC not present

Input signal 24 V DC present

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3.9 Operating hours and settings
The operating hours are called up from the main menu by touching the
symbol “operating hours and settings” or pressing the allocated key.
Fig. 56 Operating hours (example)
Editing the operating hour display is described in section3.1.3.

In this menu, the actual operating hours are displayed and the data are entered
to obtain a notification for the next service.
Display/key Meaning
Operating hours (Betriebsstunden)
Motor hour Display total separator motor operating
(Motor operating hours) hours
Productfeed hour Display of total feed valve opening time
(Product feed operating hours)
Maintenance Interval - Adjust operating hours:
(Maintenance interval - Adjusted operating hours:)
Set value Entry of the operating hours for the next
(Set) service
Actual Display of the operating hours for the next
(Actual) service
Jump to the page “settings”

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3.9.1 Settings
The settings are called up from the sub-menu “operating hours” by

touching the symbol “arrow right” or pressing the allocated key.
Fig. 57
Key Key designation
Language switching
Start operating system “Windows CE”.
Touch screen calibration

Starts the touch screen calibration
No te :
The middle of a cross must be touched with a pen to re-align
the position of the touch screen.
Contrast +
Increases contrast of screen
Contrast -
Reduces contrast of screen
Lamp test
LEDs of the control unit and external signal lamps are checked
for proper functioning.
Back to settings page
Configuration page
Call-up of machine-related settings

8555-9001-200 / 0309 87
Key Key designation
Secure process data

Save process-dependent data from control unit on the MMC.
Load process data
Load process-dependent data from the MMC to the control unit
La n g u a g e s witc hin g
Fig. 58 Language switching (example)
Up to five different languages are available, depending on the program settings.
Program number Languages
8106-0E40-000 (*) German

8106-0E40-000 (*) English
(*) The program version is indicated by the last two digits. It may change due to further technical
development.
Note: After selecting a language, the display on the operator panel is interrupted and
re-started. During this time, no data are displayed on the operator panel, the
panel starts again in the main menu (as when starting).

88 8555-9001-200 / 0309
3.10 Separator faults
3.10.1 Fault messages

A fault is signalled by disabling of the interface relay “1K12” (collective alarm),
and by a pop-up fault message window on the control unit display.
Fig. 59 Fault message (example)
The fault window shows the following information:

– A message number
– Time when the message was output
– Status of the message
C: Come (occurrence of the fault)
G: Gone (fault no longer present)
A: Acknowledged (message has been acknowledged by the operator)
– control
– The fault message in plain text
Elim in a tin g th e fa u lt m e s s a g e
The symbol “Attention” indicates at least one active fault.
• Acknowledge the message with the <ACK> key.
or
• touch this symbol in the fault message.
– The window is closed and interface relay "1K12" is re-
activated.
– If the LED in the <ACK> key flashes, at least one fault
message is still queued.

8555-9001-200 / 0309 89
3.10.2 Displaying queued fault messages
• Touch the "Attention" symbol.

– The page is displayed with the queued fault messages.
Fig. 60 Queued Fault Message (Example)
The fault window shows the following information:

– A message number
– Status of the message
K: Come (occurrence of the fault)
G: Gone (fault no longer present)
Q: Acknowledged (message has been acknowledged by the operator)
– control
– The fault message in plain text
If not all messages can be displayed simultaneously.

• Use the cursor keys to move the content of the fault message page
up or down, left or right.
The window can be closed with the X (as in Windows), or by touching the mes-
sage indicator window again.

90 8555-9001-200 / 0309
3.10.3 Displaying the fault message buffer
• Touch the symbol “fault message and operating message memo-

ry”, or press the allocated key in the main menu.
– The page is displayed with the queued fault messages.
Fig. 61 Example
An online help text is available for every fault message.
If not all messages can be displayed simultaneously.

• Use the cursor keys to move the content of the fault message
page up or down, left or right.
Display/key Meaning
Display online help text
Jump to the page “Alarm Counter”
Jump to the page “Alarm Counter”

8555-9001-200 / 0309 91
3.10.4 Register alarm messages

In the "Fault message and operating message memory" all operational separa-
tor events are numerically registered. Thus, operating modes, conditions and
events can be viewed.
For detailed information, the operating and fault-message memory is
available; this textually registers events, with the time and date.
• Touch the symbol “fault message and operating message memo-

ry”, or press the allocated key in the main menu.
– The first page is displayed with the queued fault messages.
Call-up of operating and fault message registration from the "fault

message and operating message memory" occurs by paging for-
ward.
Display Meaning
Number of motor The number of complete run-up cycles performed is

starts displayed in this line.
(Anzahl Start-
vorgänge)
Number of total The number of total ejections performed is displayed in
ejections this line.
(Anzahl Totalen-
tleerungen)
Amount of Number of WMS functions for each separation cycle
WMS/period
On a UNITROL separator with WMS system activated,
(Anzahl WMS, pe-
the number of water removals for each preset separa-
riodisch)
tion cycle is recorded. In case of a manual separation
stop, the displayed value is set to zero.
Amount of Number of WMS functions
WMS/total
On a UNITROL separator with WMS system activated,
(Anzahl WMS, to-
the number of water removals is continuously record-
tal)
ed. The displayed value cannot be reset.
Amount of Number of SMS functions for each separation cycle
SMS/period
On a UNITROL separator with SMS system activated,

92 8555-9001-200 / 0309
Display Meaning
(Anzahl SMS, pe- the number of SMS ejections for each preset separa-
riodisch) tion cycle is recorded. In case of a manual separation
stop, the displayed value is set to zero.
Amount of Number of SMS functions
SMS/total
On a UNITROL separator with SMS system activated,
(Anzahl SMS, total)
the number of ejections is continuously recorded using
SMS. The displayed value cannot be reset.
Number of black- Number of power failures
outs
The number of power failures occurred within the cur-
rent separation program is recorded.
Alarm # 01- Motor protection

Motor protection
This alarm is recorded when a switch-off is triggered
by the PCT sensors incorporated in the windings of the
separator motor.
Alarm # 02 This alarm is recorded when the separating process is
PAL 1 (DI) cut off by the minimum pressure switch installed in the
clean oil discharge line.
PAH 1 (DI) cut off by the maximum pressure switch installed in the
clean oil discharge line (optional, not standard equip-
ment).
Alarm # 04 Water discharge - Overflow
Water discharge -
This alarm is recorded when the separating process is
overflow
cut off by the maximum pressure switch installed in the
water discharge.
Alarm # 05 TAL -Clean oil feed temperature
TAL Product feed
cut off by the PT 100 temperature sensor installed in
the feed line.
Alarm # 06 TAH-Clean oil feed temperature
TAH
Product feed cut off by the PT 100 temperature sensor installed in
the feed line.
Alarm # 07 Ejection monitoring

Ejection monitoring
This alarm is recorded when the ejection program is
current
interrupted because the current monitoring device re-
sponded.

8555-9001-200 / 0309 93
Display Meaning
Alarm # 08 LAHH Sludge tank

LAHH Sludge tank
cut off by the "high/high" level limit switch installed in
the sludge tank.
Alarm #09 Feed pump fault
Feed pump fault
Response of the feed-pump motor protection switch is
recorded.
Alarm # 11 Vibration alarm - stage 1
Vibro -1
This alarm is recorded when the separator is switched
off by the (optionally available) vibration sensor in-
stalled on the separator.
Alarm # 12 Vibration alarm - stage 2
Vibro -2
This alarm is recorded when the separator is switched
off by the (optionally available) vibration sensor in-
stalled on the separator.
Alarm # 15 WMS System fault
WMS System fault
The number of continuous water removal cycles great-
er than T22 is recorded.
Alarm # 16 Water Seal
No. Water Seal
Amount of loss of the bowl water seal
Alarm # 40 Water Seal
No. Water Seal
Amount of loss of the bowl water seal
Alarm # 33 Ejection monitoring - Speed
Ejection monitoring
This alarm is recorded when the ejection program is
speed
interrupted because the speed monitoring device re-
sponded.
PAL 1 (AI) cut off by the minimum pressure switch installed in the
clean oil discharge line.
PAH 1 (AI) cut off by the maximum pressure switch installed in the
clean oil discharge line (optional, not standard equip-
ment).

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3.10.5 Status and fault indication
Fig. 63
Display Meaning
SF (red) Collective fault

This LED lights up in case of:
– Hardware errors
– Firmware errors
– Programming errors
– Parameter errors
– Computing errors
– Timer errors
– Periphery error at internal periphery functions
For precise fault determination

• Use a programming device and
• read out the diagnostic buffer.
BF (red) Bus fault at PROFIBUS-DP interface.
(option)
DC5V 5-V DC supply for the control.
(green) This LED lights up when the internal 5V power supply is ok.
FRCE Reserved
(yellow)
RUN (green) Operating status “RUN” of the control CPU.
– This LED lights up when the control is processing the user
program.
– This LED flashes (2 Hz) during the control start-up (the
STOP LED then also lights up; when the STOP LED goes
out the outputs are released).
Stop Operating status “Stop” of the control CPU.
(yellow) The LED:
– Lights when the control is not processing a user program.
– flashes slowly when the control requests a master reset,
– flashes quickly when the control executes a master reset.

8555-9001-200 / 0309 95
3.11 SwitchMicro Memory Card (MMC)

The control diagram and all settings are stored on the removable Micro Memory
Card. These data can be downloaded again when needed, e.g. when the MMC
is inserted in a new control.
ATTENTION!
The control system is not functional without an MMC, or if it is defective. The
message “CPU is in Stop” appears.
ATTENTION!
To change the Micro Memory Card, the control cabinet must be opened by suit-
ably qualified personnel.
Fig. 64
1 Status and fault indicator

2 Slot for the SIMATIC Micro Memory Card (including eject)
3 Connections of the integrated inputs and ouputs
4 Connection for the power supply
5 2. Interface X2 (PtP or DP) (option)
6 1. Interface X1 (MPI)
7 Operating mode switch

96 8555-9001-200 / 0309
ATTENTION!
The MMC may o n ly be changed when the power supply unit is switched off.
When a new Micro Memory card has been inserted, the control system is in
“STOP” mode after switching it on for the first time.
• Switch the power off and on again.
The control system is then in “RUN” mode.
ATTENTION!
The Micro Memory card may not be read with commercially available card
readers. There is a risk of destroying the program.
3.12 CPU Master Reset

Under certain circumstances, it may be necessary to carry out a master reset of
the CPU.
ATTENTION!
A master reset of the CPU means that the CPU is re-initialised.
The program currently in the RAM and all data are overwritten with the content
of the Micro Memory Card.
Fig. 65
1 Micro Memory Card (MMC)
P ro c e d u re :
• Disconnect power to the control system.
• Withdraw the Micro memory Card (1).
• Switch the power back on.

8555-9001-200 / 0309 97
• Switch it off again after approx. 30 s.

• Re-insert the Micro Memory Card (1).
– CPU is in “STOP” mode.
– CPU is in “RUN” mode.
The settings from the MCC have been loaded, the basic settings have been res-
tored.
3.13 LoadNew Visualisation

It is possible to load a new program of the operator panel user interface.
Fig. 66 Control unit
1 Slot “Compact Flash”

2 Compact Flash Card
P ro c e d u re :
• Insert the Compact Flash card (2) in slot (1).
– The loader is b rie fly displayed in the start phase of the operator panel.

98 8555-9001-200 / 0309
• Touch the Control Panel” button in

the loader.
– The control panel (visualisation
device) of the operator panel
opens.
Fig. 67 Loader
Fig. 68 Control Panel
• Open the button “backup/Restore” with a double click.
• Touch the “RESTORE”button.

– The message is output.
“Restore starting”
– Then follows the message:
“Checking data”
– After the check is complete, the
following message is displayed.
“You are now starting the restore
procedure. All files with the excep-
tion of the files on the memory
card and the registration files will
be deleted. Are you sure?”
Fig. 69 Backup/Restore

8555-9001-200 / 0309 99
If th e d a ta a re to b e re s to re d ,
• touch “Yes”.
During the restore procedure, the following messages are displayed:
– “Deleting files in the internal flash memory” and
– “Restoring CE image”
A status bar shows the progress.
The restore procedure end with the message:
“Restoring the CE image complete”. The operator panel is now re-started. Do
not remove the memory card”
If th e re s to re p ro c e d u re is o b e a b o rte d ,
• touch “No”.
• Touch the “OK” button.

– The operating system is loaded whereby the loader and control panel are
opened successively. Two messages then follow. The final message
follows:
“Restore successfully completed”. Touch OK and remove the memory
card.”
• Touch the “OK” button.
– The operator panel boots. The control panel is then displayed.
• Remove the memory card as required.
– Keep the memory card in a safe place.

100 8555-9001-200 / 0309
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note

8555-9001-200 / 0309 101
4 Maintenance and servicing
4.1 PreventingAccidents ........................................................................ 102

4.1.1 Demands on the operating and maintenance personnel ..................... 102
4.1.2 Spare part requirements ...................................................................... 103

102 8555-9001-200 / 0309
4.1 PreventingAccidents
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 con-

cerning maintenance and repairs are repeated here again.
Before carrying out maintenance and

repair work:
• Switch off all electrical appliances via the
main switch.
• Lock the installation to prevent it from
being accidentally switched on.
Fig. 70

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

who
ing.
The operator of the separator, the control system or the separator plant
• must be sure that the personnel have read and understood the manuals ne-
cessary to carry out their work.

courses. For more in-depth information, please check back with Westfalia Sepa-
rator or one of their authorised agencies.

8555-9001-200 / 0309 103

Separator! The original spare parts are listed in
the circuit diagram. The circuit diagram is lo-
cated on the control cabinet door.
– safety risks,
– reduced availability of the control unit
Fig. 71
ranty claims.

104 8555-9001-200 / 0309
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note

8555-9001-200 / 0309 105
5 Installation - Electrical connection
5.1 Connect control unit ............................................................................. 106

5.2 Electrical connection ............................................................................ 107
5.3 Fuse terminals ..................................................................................... 107
5.4 Central control via potential-free contacts ........................................... 108

106 8555-9001-200 / 0309
5.1 Connect control unit
ATTENTION!
• Special attention must be paid to the installation guidelines of Westfalia Sepa-
rator.
Note: 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
ATTENTION!
• Connect the control system only to voltages that are specified on the namep-
late inside the control cabinet.
The standard rating for the control voltage for solenoid valvesfor operating water
and control air is 24 VDC.
CAUTION! Danger through external voltage!

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 threading in the leads.

8555-9001-200 / 0309 107

The control unit is designed for a mains voltage as indicated on the name-plate
inside the control cabinet. The required control voltages of 230 AC and 24 VDC
are auto-generated.
ATTENTION!
Before operating the control unit, check the rated voltage indicated on the na-
meplate inside the cabinet.
Please make sure

– that the solenoid valves of the plant are designed for 24 V DC.
– that the lead-in wires to the control unit are protected by means of the fuses
specified in the project-related circuit diagram.
CAUTION! Danger due to electrical voltage!

The potential-free contacts of the output modules carry external voltage
(even when the main switch is off!).
The voltage-free contacts of the output modules

– can be identified by the orange-coloured wiring.
– can be included in circuits with any voltage of 250 VAC.
Switching capacity of the contacts: see technical data.
2
A wire cross-section of 1.0 mm Cu is adequate for all cables.
The arrangement of the terminals on terminal strip X1 is shown in the terminal
diagram (see the electrical documentation).
• The screwed glands for threading in the electrical cables should be properly
tightened and
• packed with sealing compound.
5.3 Fuse terminals

Valve actuation is via fuse terminals with LED indicators.
In case of short-circuit in the valve control circuit, the fuse of the relevant ter-
minal will respond. This failure is signalled by the corresponding red LED. This
single fuse ensures the full functionality of the controls as the operating voltage
of 24 V DC is still available. The electronic fuse in the power supply module is
not activated.
ATTENTION!
When the safety system has responded, the functionality of the control system
is restricted.
• Eliminate the cause of trouble immediately!
Spare fuses "0.5 A - semi-time lag" are supplied with the control cabinet.

108 8555-9001-200 / 0309
5.4 Central control via potential-free contacts

The integration of local plant controls in customer central controls require clarifi-
cation of the communication signals when placing the order.
The WS control can only be interfaced with a central control via hardware sig-
nals. The signal exchange sequence is as follows:
Customer
WS Control
central control
Functions executed Signals
Collective alarm Collective = 1
Low temperature fault - TAL Temperature low = 1
High temperature fault - TAH Temperature high = 1
Water seal alarm fault Water seal lost = 1

8555-9001-200 / 0309 109
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note

110 8555-9001-200 / 0309
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note

8555-9001-200 / 0309 111

Phone: +49 2522 77-0 · Fax: +49 2522 77-17 78
Westfalia Separator
Division
Parameter and Trouble Shooting
No.: 8555-9201-100
Edition: 0806
Designation: Parameter and trouble shooting
Model: D20
Westfalia Separator
GEA Westfalia Separator Mineraloil Systems GmbH
Werner-Habig-Str. 1
D-59302 Oelde
8555-9201-100 / 0806
Westfalia Separator
8555-9201-100 / 0806
Westfalia Separator
Parameter and Trouble Shooting 1
1 Timer overview 7
1.1 Timerlist OSD 6 ...................................................................................................8
1.2 Timerlist OSD 18 .................................................................................................9
1.3 Timerlist OSD 35 ...............................................................................................10
1.4 Timerlist OSD 60 ...............................................................................................11
1.5 Timer 47- Pump related time sheet ...................................................................13
1.6 Bowl volumes ....................................................................................................13
1.7 Machine related Speeds....................................................................................13
1.8 Timer description - Timetable 1 .........................................................................14
2 Counter overview 17
2.1 Counterlist OSD 6 .............................................................................................18
2.2 Counterlist OSD 18 ...........................................................................................19
2.3 Counterlist OSD 35 ...........................................................................................20
2.4 Counterlist OSD 60 ...........................................................................................21
2.5 Counter description ...........................................................................................22
3 Process Logic 23
3.1 Program Logic - Diagram - 0136 - HFO - ..........................................................24
3.2 Program Logic - Diagram - 0196 - LO - .............................................................34
4 Trouble Shooting - Operating faults summary 43

4.1 Motor Protection Alarm #01...............................................................................44
4.2 PAL 1 Clean Oil Discharge Alarm #02 ..............................................................45
4.3 PAH 1 Clean Oil Discharge Alarm #03 ..............................................................46
4.4 TAL OIL Feed Alarm #05...................................................................................47
4.5 TAH OIL Feed Alarm #06 ..................................................................................48
4.6 Ejection Monitoring Alarm #07...........................................................................49
4.7 LAHH Sludge Tank Alarm #08 ..........................................................................50
4.8 Feed Pump Fault Alarm #09..............................................................................51
4.9 Sludge Pump Fault Alarm #10...........................................................................52
4.10 Min. Separating Time Alarm #14 .......................................................................53
4.11 WMS system Fault Alarm #15 ...........................................................................54
4.12 No Water Seal Alarm #16..................................................................................55
4.13 PSL 1 Monitoring Alarm #17..............................................................................56
4.14 Bowl Monitoring Alarm #18................................................................................57
4.15 Separator Motor Off Alarm #19 .........................................................................58
4.16 SMS Sensor Fault Alarm #20 ............................................................................59
4.17 WMS Sensor Fault Alarm #21 ...........................................................................60
4.18 Excessive Running Time Of Sludge Pump Alarm #22 ......................................61
4.19 WMS Activated Too Often Alarm #23................................................................62
4.20 SMS Sensor Active Alarm #24 ..........................................................................63
4.21 Maintenance Alarm #27.....................................................................................64
4.22 Warning Water content >0.5% Warning Alarm #28 ...........................................65
4.23 TAL OIL Feed Warning Alarm #31 ....................................................................66
4.24 TAH OIL Feed Warning Alarm #32....................................................................67
4.25 Ejection Monitoring Alarm #33...........................................................................68
4.26 Bowl Monitoring speed Alarm #34.....................................................................69
4.27 Motor Start monitoring Alarm #35......................................................................70
8555-9201-100 / 0806
Westfalia Separator
4.28 Belt monitoring Alarm #36 .................................................................................71

4.29 Max.- speed monitoring Alarm #37....................................................................72
4.30 Min.- speed monitoring Alarm #38.....................................................................73
4.31 PT 1 MONITORING Alarm #39 .........................................................................74
4.32 No Water Seal Alarm #40..................................................................................75
4.33 Min. Separating Time Alarm #41 .......................................................................76
4.34 SMS Sensor Fault Alarm #42 ............................................................................77
4.35 SMS Sensor Active Alarm #43 ..........................................................................78
4.36 PAL 1 Clean Oil Discharge Alarm #44 ..............................................................79
4.37 PAH 1 Clean Oil Discharge Alarm #45 ..............................................................80
4.38 EMERGENCY STOP Alarm #46 .......................................................................81
5 Alarm simulation and test 83

5.1 Alarms #01 - #18 ...............................................................................................84
5.2 Alarms #19 - #37 ...............................................................................................85
5.3 Alarms #38 - #46 ...............................................................................................86
6 Ejection / Bowl monitoring 87

6.1 General description ...........................................................................................88
6.1 Graphic description ...........................................................................................89
6.2 General description Speed monitoring with speed pick-up................................90
8555-9201-100 / 0806
Westfalia Separator
8555-9201-100 / 0806
Westfalia Separator
1 Timer overview
8555-9201-100 / 0806
Westfalia Separator
1.1 Timerlist OSD 6
Description Separator Type

Display Text D20 OSD 6 OSD 6
Full Text Remarks:
Control Unit HFO 0136 LO 0196
lower upper lower upper

Factory Factory
Timer *1.) time
setting
time time
setting
time
limit limit limit limit
T0 Partial ejection Partial ejection 0 0

T1 Displacement water Displacement 5 8 10 5 8 10
T2 Filling water Filling 6 9 11 6 9 11
T3 Waiting Waiting 10 10
T4 Total ejection Total ejection 2 2
T5 Speed recovery after Total ejection Speed rec.Total 8 8
T6 Closing water impulse Closingwater imp 0,05 0,05
T7 Alarm delay Alarm delay 15 20 25 15 20 25
T8 Waiting after displacement Wait aft.displac 2 2
T9 Waiting after filling Wait aft.filling 2 2
T10 Separator starting Separator Start 240 240
T11 Alarm Bridging Alarm-bridging 15 30 40 15 30 40
T12 Waiting after 1. ejection Wait aft.1.Eject 10 10
T13 Speed recovery after partial ejection Speed rec.part. 0 0
T14 Closing water interval Closing Interval 600 900 1800 600 900 1800
T15 Circulation valve close Circ.valve clos 60 0
T16 Circulation valve open Circ.valve open 5 0
T17 Free Free - -
T18 Sludge tank alarm delay LSHH-Sludgetank 10 10
T19 Water impulse by start Wat.Imp.by start 3 3
T20 Separation Separation no password 3600 3600
T21 Min separation time with SMS Min-Sep.-Time 600 0
T22 High water content High water cont. 2 60 80 2 10 30
T23 Feed pump delay Feedpump delay 300 300
T24 Sludge pump delay off Sludgep.delay 60 60
T25 Vibration 1 delay Vibro 1 option 0 0
T27 SMS low pressure delay SMS PSL delay 5 10 15 0
T28 Ejection monitoring Ejection monitor 3 3
T29 Brake for separator Brake for Sep. option 300 300
T30 Cooling Interval Cooling interval option 0 0
T31 Cooling water Cooling water option 0 0
T32 WMS-Mode WMS-Mode 0 3600
T33 SMS-Mode SMS-Mode 0 0
T34 Circulation valve delay Circ.valve delay 0 1 10 20
T35 Water seal broken delay Water.Seal brok. 0 1 1 40
T36 SMS pressure check SMS Press.Check 0 1 2
T37 SMS Waiting SMS Waiting 0 3
T38 WMS Sensor flushing WMS Sensor flush 0 20
T39 Separator off after idle run Separator off 1800 1800
T40 Free Free - -
T41 Free Free - -
T42 Free Free - -
T43 Free Free - -
T44 SMS-Sensor-Check SMS-Sensor-Check 25 35 50 25 35 50
T45 WMS-Sensor-Check WMS-Sensor-Check 300 20
T46 Free Free - -
T47 Min.SMS Time Min.SMS Time 0 2 18 20
T60 Start Impulse Start Impulse internal timer 10 10
T61 Sensor interval Sensor interval internal timer 2 2
T62 Sensor impulse Sensor impulse internal timer 1 1
8555-9201-100 / 0806
Westfalia Separator
1.2 Timerlist OSD 18
Separator Type
Full Text Remarks:

Factory Factory
Timer *1.) time
setting
time time
setting
time

T4 Total ejection Total ejection 2,5 2,5
T17 Free Free - -
T40 Free Free - 0
T41 Free Free - -
T42 Free Free - -
T43 Free Free - -
T46 Free Free - -
8555-9201-100 / 0806
Westfalia Separator

Full Text Remarks:

Factory Factory
Timer *1.) time
setting
time time
setting
time

T17 Free Free - -
T40 Free Free - -
T41 Free Free - -
T42 Free Free - -
T43 Free Free - -
T46 Free Free - -
T47 Min.SMS Time Min.SMS Time 0 1 3,5 9
8555-9201-100 / 0806
Westfalia Separator

Full Text Remarks:

Factory Factory
Timer *1.) time
setting
time time
setting
time

T17 Free Free - -
T40 Free Free - -
T41 Free Free - -
T42 Free Free - -
T43 Free Free - -
T46 Free Free - -
8555-9201-100 / 0806
Westfalia Separator
8555-9201-100 / 0806
Westfalia Separator
1.5 Timer 47- Pump related time sheet
Separator Type Feed pump capacity T 47 [sec.]

LO -0196- [L/h]
OSD 6 600 18
OSD 18 1500 7
OSD 35 3000 3,5
OSD 60 6000 5
All values in the chart subject to modification!
1.6 Bowl volumes
OSD 6 OSD 18 OSD 35 OSD 60

HFO LO HFO LO HFO LO HFO LO
Bowl volume 1,42 1,42 3,00 3,00 8,00 8,00 20,00 20,00
Sludge space
0,90 0,90 1,50 1,50 4,00 4,00 11,00 11,00
volume
Fillingwater
0,85* 0,85 1,30* 1,30 5,00* 4,00 5,00* 11,00
volume
Displacement-
1,00 0,80 2,00 1,30 5,00 3,00 14,00 10,00
water volume
* only during WMS Sensor Check!
1.7 Machine related Speeds
Machine type OSD 6 OSD 18 OSD 18 OSD 35 OSD 60

Execution 8/10 15/18
Max. Speed 13000 10700 12400 8900 7200
Min. Speed 11500 9400 11200 8000 6400
Rated Speed 12000 10000 11500 8200 6800
Speed Offset 100 100 100 100 100
Ejection monitoring
Speed Offset 100 100 100 100 100
Bowl monitoring
8555-9201-100 / 0806
Westfalia Separator
1.8 Timer description - Timetable 1
Timer
Designation: Action / Status: Description: Aktive in:
No:
- HFO- -LO -
The bowl sludge space is partial emptied by
T00 Partial ejection Operating water valve V 3 opens actuating the operating water valve V 3. --- ---
(Option)
The bowl contents are displaced without loss by
opening V 2. If preselected in the program, the
T01 Displacement water Displacement water valve V 2 opens X X
setting will be taken from the automatic
computing function during the sensor test.
The filling process creates the required water
seal inside the bowl by openining V 2. If
preselected in the program, the setting will be
T02 Filling water Filling water valve V 2 opens taken from the automatic computing function X X
during the sensor test. Filling water is also
active during WMS-Sensor Check for HFO
seprators.
After pressing start/stop, the timer is activated
Oil feed valve V 1 closes. Clean oil
T03 Waiting before the displacement water function is X X
discharge pressure is reduced.
initiated.
The bowl sludge space is emptied by actuating
T04 Total ejection Operating water valve V 3 opens X X
the operating water valve V 3.
Speed recovery Timer to compensate a speed drop occured
T05 X X
after total ejection during total ejection.
Closing water Timer for safety water to keep the bowl closed
T06 Operating water valve V 3 opens X X
impulse during separation.
a) PAL clean oil discharge X X
b) PAH clean oil discharge X X
After timer is expired, product feed valve
T07 Alarm delay c) FREE --- ---
V 1 closes.
d) TAL oil feed X X
e) TAH oil feed X X
Waiting after Timer to stabilize the system after
T08 X X
displacement displacement process.
Timer to stabilize the system after filling
T09 Waiting after filling X X
process.
Start button of motor starter activated and Timer for monitoring operating speed after
T10 Separator starting X X
start-up of separator motor. motor start.
T11 Alarm Bridging Alarms not activated. Timer to stabilize the process conditions! X X
Waiting after 1. Timer to compensate a speed drop occured
T12 X X
ejection during 1. ejection.
Speed recovery
Timer to compensate a speed drop occured
T13 after partial X X
during partial ejection. (Option)
ejection
Closing water Time interval between two closing water
T14 X X
interval pulses.
Circulation valve
T15 Circulation valve V 5 closes. Timer in which the circulation valve is closed! X ---
close
Circulation valve Circulation valve V 5 opens. Timer in which the circulation valve is opened!
T16 X ---
open WMS Sensor is activated. WMS Sensor Signal is checked.
T17 Free --- ---

Sludge tank alarm Alarm is activated when timer has elapsed.
T18 Timer delay for sludge tank alarm. X X
delay Start of ejection program.
Water impulse by Timer for closing the bowl after separator is on
T19 Operating water valve V 3 opens X X
start operating speed.
T20 Separation Product feed valve V 1 opens Timer for adjusting the separating time. X X
In case of pressure drop (SMS PT 2) during Timer in which a system pressure drop is
Min. separation
T21 T21 , triggering of alarm "Minimum evaluated as an alarm. Timer starts together X ---
time with SMS
separating time during SMS" with timer 20.
Alarm is activated when timer has elapsed.
Timer to trigger the alarm "High water
The water discharge valve V 6 is open
content" only when the WMS sensor senses
T22 High water content while T 22 is activated, water discharge X X
water during timer T 22. The timer is activated
valve V 6 is then closed and oil feed valve
only when SMS sensor PT 2 senses pressure.
V 1 goes into circulation mode!
Feed pump is switched off after preset Timer which switches off the feed pump after a
T23 Feed pump delay X X
delay time of T23. delay time so that the heaters can cool off!
Timer which switches off the sludge pump after
Sludge pump delay After delay time of T 24, sludge pump is
T24 a delay time to ensure that the sludge tank is X X
off switched off.
emptied completely.
8555-9201-100 / 0806
Westfalia Separator
Timer
No:
- HFO- -LO -
Timer which triggers the alarm "Vibration
After delay time of T 25, an ejection is
T25 Vibration 1 delay stage 1" only when the signal is activated for option option
initiated.
the time T 25!
After delay time of T 26, the safety water
Timer which triggers the alarm "Vibration stage
valve V 2 is opened and the pneumatic
T26 Vibration 2 delay 2" when the signal is activated for the time T option option
brake (option) actuated. The separator
26!
motor is shut down immediately.
After delay time of T 27 within time T 21 Timer which triggers the alarm "Min separating
SMS low pressure
T27 an alarm and ejection is triggered in case time" when the signal is activated for the time X ---
delay
of pressure drop! T 27!
Timer which triggers the alarm "Ejection
Monitoring of motor current or speed
monitoring" when the motor current measured
during ejection phase. An ejection is
T28 Ejection monitoring during this time does not exceed the preset X X
initiated and the product feed valve V 1
offset value or the speed measured during this
switched to circulation mode.
time does not exceed the preset speed offset
Timer which automatically brakes the separator
T29 Brake for separator Brake is actuated for time T 29. option option
after an alarm "Vibration stage 2".
T30 Free --- ---
T31 Free --- ---
Water discharge valve V 6 closes. Timer for process monitoring during
T32 WMS-Mode --- X
Circulation valve V 5 closes. separation!
Timer for sludge space monitoring. Only the
Water discharge valve V 6 closes.
T33 SMS-Mode SMS sensor PT 2 is activated. The sludge content --- X
Circulation valve V 5 closes.
of the bowl is checked.
Circulation valve V 5 closes. Water
Circulation valve
T34 discharge valve V 6 opens and closes after Timer to flush the WMS sensor. --- X
delay
run-down of the timer.
Circulation valve V 5 opens. Timer which triggers the alarm "Water seal
Water seal broken Water discharge valve V 6 closes. broken" only when the WMS sensor senses oil
T35 --- X
delay Triggering of alarm "water seal broken" for the time T 35. The timer is activated only
after timer run-down. when SMS sensor PT 2 senses pressure.
Bowl is filled in intervals controlled by T37 with
filling water to check whether the sludge space
Filling water valve V 2 opens in intervals is filled with sludge. If the sludge space is not
T36 SMS pressure check --- X
until SMS sensor PT 2 is activated. full, the SMS sensor PT 2 must respond to
pressure. If pressure is not increasing, an
ejection is triggered.
Timer to set the interval between two filling
Filling water valve V 2 closes.
T37 SMS waiting water pulses for sludge space monitoring! See --- X
SMS sensor PT 2 is activated.
also SMS pressure check, above.
WMS sensor not activated. Timer to flush the sensing line after the first
WMS Sensor
T38 SMS sensor PT 2 not activated. program start so that it is clean and excessive --- X
flushing
Water discharge valve V 6 opens. filling water is discharged!
Separator off after After delay T 39, the separator motor is Timer delay for separator motor stop. Function
T39 X X
idle run switched off. must be preselected in the program.
8555-9201-100 / 0806
Westfalia Separator
Timer
No:
- HFO- -LO -
Circulation valve V 5 closes.
Water discharge valve V 6 closes.
SMS sensor PT 2 is activated. Timer in which the function of the SMS
T44 SMS Sensor check X X
If T44 is elapsed without SMS Sensor PT 2 sensor PT 2 is tested.
Signal, Alarm "SMS sensor failure during
WMS-SMS check" is triggered.
Circulation valve V 5 closes (only LO-0196).
Water discharge valve V 6 opens (only LO-
0196).
Circulation valve open close function T15-
Timer in which the function of the WMS sensor
T45 WMS Sensor check T16 (only HFO-0136). X X
is tested.
WMS Sensor is activated.
If T45 is elapsed without WMS Sensor
Signal, alarm "WMS sensor failure during
WMS-SMS check" is triggered.
T46 Free --- ---
Capacity and machine type-dependent timer
which determines the 0.5vol% content of water
When SMS Sensor PT 2 is activated while
in the lube oil during WMS mode. The pressure
T 47 is running, the water discharge
T47 Min. SMS time increase is evaluated as a function of T 47 over --- X
valve V 6 is opened for 3 seconds and
several successive cycles which are defined via
Counter 5 counts the PT 2 signal.
counter 5 "SMS time interval 0,5vol% water
content"
Timer to fill filling water into the bowl. This
timer runs before timer T61 and T62. Timer is
T60 Start impulse Filling water valve V 2 opens. X X
required for the automatic calculation of timers
01 and 02. Timer is protected.
Timer to set the interval between two sensor
T61 Sensor interval Filling water valve V 2 closes. X X
impulses, T62. Timer is protected.
Timer to fill filling water into the separator
bowl. This timer operates pulse-wise together
T62 Sensor impulse Filling water valve V 2 opens. with timer T61 after timer T60. Timer is X X
required for the automatic calculation of the
timers 01 and 02. Timer is protected.
8555-9201-100 / 0806
Westfalia Separator
2 Counter overview
8555-9201-100 / 0806
Westfalia Separator
2.1 Counterlist OSD 6

Description
Display Text D10/D20 OSD 6 OSD 6
Full Text Remarks:
Factory Factory
setting setting
Counter [ amount ]
C1 Flushing Count
C1 Flushing Counter Flushing Counter P: 5 5 5
A: 0
C3: SMS Filling

C3 SMS Filling SMS Filling Counter P: 3 - 3
A: 0
C4: Sensor check

C4 Sensor check Sensor Check Counter P: 5 10 10
A: 0
C5: SMS time interval
C5 SMS time interval SMS Time interval counter for 0,5vol% water cont
- 5
0,5vol% water cont 0,5vol% water content warning P: 5
A: 0
Time Records [ min ]
WMS Time
Timerecords for WMS Time
Max in 24h 60min
TR1 WMS Time during operation in last TR3
Act. In 24h 0min
60 60
(24h) hours.
Last 24h 0min
Sludgep. Time
Timerecords for Sludgepump
Max in 24h 20min
TR2 Sludgep. Time time operation in last TR3 (24h)
Act. In 24h 0min
20 30
hours.
Last 24h 0min
Time Record reset
Reset of all Time Records after
TR3 Time Records reset TR3 (24h).
P: 24 24h 24h
A: 0
Other Alarms see

Only Alarms that have
Alarms adjustable values!
Trouble Shooting [ °C ]
List!
Value depending
Warning TAH OIL FEED
to the setpoint of
Warning for an increase of the Temp. > max
TAH OIL FEED oil temperature. Warning
the Offset! 105 100
Temp. > max See Analog Input
Alarm#32 press HELP
list!
Value depending
Warning TAL OIL FEED
to the setpoint of
Warning for a decrease of the Temp. < min
TAL OIL FEED oil temperature. Warning
the Offset! 95 80
Temp. < min See Analog Input
Alarm#31 press HELP
list!
TAH OIL FEED
TAH OIL FEED Alarm for an increase of the oil Temp. > max
110 105
Temp. > max temperature. Separation-Stop
Alarm#06 press HELP
TAL OIL FEED
TAL OIL FEED Alarm for a decrease of the oil Temp. < min
90 75
Temp. < min temperature. Separation-Stop
Alarm#05 press HELP
[A]
Value depending
EJECTION MONITORING:
Alarm for monitoring the on the conditions
Ejection monitoring Eject. current < Offset
ejection after separation or of the power 0,5 0,5
Eject. current < Offset Separation-Stop
after SMS ejection. supply system and
Alarm#07 press HELP
the clutch shoes!
[ rpm ]
Value depending
Ejection monitoring Eject. speed < Offset
ejection after separation or of the power 100 100
Eject. speed < Offset Separation-Stop
Alarm#33 press HELP
the clutch shoes!
8555-9201-100 / 0806
Westfalia Separator

Description
Full Text Remarks:
Factory Factory
setting setting
Counter [ amount ]
C1 Flushing Count
A: 0
C3: SMS Filling

A: 0
C4: Sensor check

A: 0
- 5
A: 0
WMS Time
Max in 24h 150min
Act. In 24h 0min
150 150
(24h) hours.
Last 24h 0min
Sludgep. Time
Max in 24h 20min
Act. In 24h 0min
20 30
hours.
Last 24h 0min
Time Record reset
P: 24 24h 24h
A: 0
Other Alarms see

List!
Value depending
to the setpoint of
the Offset! 105 100
Alarm#32 press HELP
list!
Value depending
to the setpoint of
the Offset! 95 80
Alarm#31 press HELP
list!
TAH OIL FEED
110 105
Alarm#06 press HELP
TAL OIL FEED
90 75
Alarm#05 press HELP
[A]
Value depending
ejection after separation or of the power 0,5 0,5
Alarm#07 press HELP
the clutch shoes!
[ rpm ]
Value depending
Alarm#33 press HELP
the clutch shoes!
8555-9201-100 / 0806
Westfalia Separator

Description
Full Text Remarks:
Factory Factory
setting setting
Counter [ amount ]
C1 Flushing Count
A: 0
C3: SMS Filling

A: 0
C4: Sensor check

A: 0
- 5
A: 0
WMS Time
Max in 24h 150min
Act. In 24h 0min
150 150
(24h) hours.
Last 24h 0min
Sludgep. Time
Max in 24h 30min
Act. In 24h 0min
30 40
hours.
Last 24h 0min
Time Record reset
P: 24 24h 24h
A: 0
Other Alarms see

List!
Value depending
to the setpoint of
the Offset! 105 100
Alarm#32 press HELP
list!
Value depending
to the setpoint of
the Offset! 95 80
Alarm#31 press HELP
list!
TAH OIL FEED
110 105
Alarm#06 press HELP
TAL OIL FEED
90 75
Alarm#05 press HELP
[A]
Value depending
Alarm#07 press HELP
the clutch shoes!
[ rpm ]
Value depending
Alarm#33 press HELP
the clutch shoes!
8555-9201-100 / 0806
Westfalia Separator

Description
Full Text Remarks:
Factory Factory
setting setting
Counter [ amount ]
C1 Flushing Count
A: 0
C3: SMS Filling

A: 0
C4: Sensor check

A: 0
- 5
A: 0
WMS Time
Max in 24h 240min
Act. In 24h 0min
240 240
(24h) hours.
Last 24h 0min
Sludgep. Time
Max in 24h 40min
Act. In 24h 0min
40 50
hours.
Last 24h 0min
Time Record reset
P: 24 24h 24h
A: 0
Other Alarms see

List!
Value depending
to the setpoint of
the Offset! 105 100
Alarm#32 press HELP
list!
Value depending
to the setpoint of
the Offset! 95 80
Alarm#31 press HELP
list!
TAH OIL FEED
110 105
Alarm#06 press HELP
TAL OIL FEED
90 75
Alarm#05 press HELP
[A]
Value depending
Alarm#07 press HELP
the clutch shoes!
[ rpm ]
Value depending
Alarm#33 press HELP
the clutch shoes!
8555-9201-100 / 0806
Westfalia Separator
2.5 Counter description

Counter
Designitation: Status: Description: Aktive in:
No.:
- 0136 - - 0196 -
Counter after how many
ejections a doubled ejection for
C1 Flushing Counter Counter for ejection X X
flushing the bowl will be
initiated.
C2 Free --- ---
Counter for Fillingwater Counter for amount of
C3 SMS Filling Counter impulse after SMS Mode fillingwater impulses after SMS --- X
T33. Mode T33.
Counter after how many
ejections the SMS and WMS
Sensor Check Sensor Check will be initiated.
C4 Counter for Sensor check X X
Counter WMS Sensor Check only if no
water signal was indicated
during running sequence.
Counter for counting how
SMS Time interval many consecutive times SMS
Counter for SMS Sensor
counter for 0,5vol% Sensor PT 2 was activated
C5 signal during WMS --- X
water content shorter than T47. Gives alarm,
Mode.
warning when water content is over
0.5%.
Time
Records
No.:
During operation, the Time where
the WMS-Sensor is activated due
TR1 WMS Time to water indication, will be X X
recorded. Timerecords will be
deleted when TR3 is expired.
Timerecords for recording the

time where the sludge pump is in
TR2 Sludgepumpe Time X X
operation. Timerecords will be
deleted when TR3 is expired.
When the presetted time is
TR3 Time Records reset expired all Timerecords will be X X
deleted.
8555-9201-100 / 0806
Westfalia Separator
3 Process Logic
8555-9201-100 / 0806
Westfalia Separator
3.1 Program Logic - Diagram - 0136 - HFO -
8555-9201-100 / 0806
Westfalia Separator
Program Logic - Diagram - 0136 - HFO - Legend Components
8555-9201-100 / 0806
Westfalia Separator
Program Logic - Diagram - 0136 - HFO -Legend Pipes/Tank
8555-9201-100 / 0806
Westfalia Separator
Program Logic - Diagram - 0136 - Chapter “A”
8555-9201-100 / 0806
Westfalia Separator
Program Logic - Diagram - 0136 - Chapter “B”
8555-9201-100 / 0806
Westfalia Separator
Program Logic - Diagram - 0136 - Chapter “C”
8555-9201-100 / 0806
Westfalia Separator
Program Logic - Diagram - 0136 - Chapter “D”
8555-9201-100 / 0806
Westfalia Separator
Program Logic - Diagram - 0136 - Chapter “E”
8555-9201-100 / 0806
Westfalia Separator
Program Logic - Diagram - 0136 - Chapter “F”
8555-9201-100 / 0806
Westfalia Separator
8555-9201-100 / 0806
Westfalia Separator
3.2 Program Logic - Diagram - 0196 - LO -
8555-9201-100 / 0806
Westfalia Separator
Program Logic - Diagram - 0196 - LO - Legend Components
8555-9201-100 / 0806
Westfalia Separator
Program Logic - Diagram - 0196 - LO - Legend Pipes/Tank
8555-9201-100 / 0806
Westfalia Separator
Program Logic - Diagram - 0196 - Chapter “A”
8555-9201-100 / 0806
Westfalia Separator
Program Logic - Diagram - 0196 - Chapter “B”
8555-9201-100 / 0806
Westfalia Separator
Program Logic - Diagram - 0196 - Chapter “C”
8555-9201-100 / 0806
Westfalia Separator
Program Logic - Diagram - 0196 - Chapter “D”
8555-9201-100 / 0806
Westfalia Separator
Program Logic - Diagram - 0196 - Chapter “E”
8555-9201-100 / 0806
Westfalia Separator
Program Logic - Diagram - 0196 - Chapter “F”
8555-9201-100 / 0806
Westfalia Separator
4 Trouble Shooting - Operating faults summary
8555-9201-100 / 0806
Westfalia Separator
4.1 Motor Protection Alarm #01

No. Status PLC
X YY D 20
MOTOR PROTECTION Temp. > max temp. Motor shut off
Alarm#01 press HELP for info
x and yy = system data
Display shows Possible causes Remedy

• No motor protection switch signal Check functionality of motor protection
switch
• Brake not released Release brake
• Thermistor relay has triggered Check thermistor relay and cabling
• Operating water valve V2 open Check operating water valve V2
• Drive blocked Check drive
• Wrong number of clutch shoes Check number of clutch shoes
• Feed capacity too high Check capacity
• Motor ventilation not adequate Improve motor ventilation
• max temp. = see motor plate
Help text – Information on control
HELP Step 1 Open HELP - menu
MOTOR PROTECTION
Alarm#01 Please check:
Motor protection function / Brake
Thermistor relay / Operating water
Valve V2 / No. of clutch shoes
Drive blocked / Feed capacity
Press ESC then ACK
ESC Step 2 Back to alarm message
ACK Step 3 Alarm acknowledgement
8555-9201-100 / 0806
Westfalia Separator
4.2 PAL 1 Clean Oil Discharge Alarm #02

No. Status PLC
X YY D 20
PAL 1 CLEAN OIL DISCHARGE Pressure < setting

• Clean oil discharge valve V7 Check valve setting V7
opened too wide
• Feed capacity reduced Check feed capacity
• Setting PSL1 for PAL1 too high Check setting PSL1 for PAL 1
see also PAH1 alarm
• Water pressure for hydraulics too Check water pressure with opened
high during T06, bowl has opened valve V3
• Safety pulse T06 too long, bowl has Check TIMER 06
opened
• Feed pump failure Check feed pump
• FU speed too low Check pump speed
• Feed valve V1 in circulation position Check compressed air and signal out-
put for solenoid valve on V1
• Breakover to water side Check quantity of filling water
• Direction of rotation of pump incor- Check direction of rotation
rect
• Bowl gaskets not sealed Check and where necessary replace
gaskets
• T07 alarm delay too short Check whether T07 expires before
pressure builds up
• T11 alarm bridging too short Check TIMER 11 alarm bridging
• FU = Frequency transformer
PAL1 CLEAN OIL DISCHARGE

Valve setting V7 / Feed capacity
Setting PSL1 for PAL / Water pressure for
opened valve V3 / TIMER 06 /T07 alarm
delay / Quantity of water / Bowl not sealed
Press ESC then ACK
Step 3 Alarm acknowledgement

ACK
8555-9201-100 / 0806
Westfalia Separator
4.3 PAH 1 Clean Oil Discharge Alarm #03

No. Status PLC
X YY D 20
PAH 1 CLEAN OIL DISCHARGE Pressure > setting
x and yy = system
data

• Clean oil discharge valve V7 closed Check valve setting V7
too far
• Feed capacity too high Check feed capacity
• Setting PSH1 for PAH1 too low Check setting PSH1 for PAH 1
• T07 alarm delay too short Check T07
• T11 alarm bridging too short Check T11 alarm bridging
• Oil temperature too low Check temperature in oil feed
PAH1 CLEAN OIL DISCHARGE

Valve setting V7 / Feed capacity /
Setting PSH1 for PAH / T07 alarm delay
T11 alarm bridging /
Temperature oil feed
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.4 TAL OIL Feed Alarm #05

No. Status PLC
X YY D 20
TAL OIL FEED Temp. < min Separation - Stop

• Oil too cold before pre-heater Check settling tank temperature
(Settling tank applies to HFO only)
• Setting TAL has been set too high Check setting TAL
• Temperature of heating medium is Check temperature of heating medium
too low
• Temperature regulator defective Check temperature regulator
• E-pre-heater basic load or regulating Check switching stages electrically
stage switched
• Pre-heater dirty Check pre-heater
• PT100 sensor defective Check sensor
TAL OIL FEED

Settling tank temp. / Feed capacity
Setting TAL / Temp. of heating medium
Temp. regulator def./ Switching stages
elect. pre-heater / PT 100 sensor
Press ESC then ACK
Step 3 Alarm acknowledgement

ACK
8555-9201-100 / 0806
Westfalia Separator
4.5 TAH OIL Feed Alarm #06

No. Status PLC
X YY D 20
TAH OIL FEED Temp. > max Separation - Stop

• Oil too hot Check regulating valve
• Feed capacity too low Check feed capacity
• Setting TAH too low Check setting TAH
stages switched
• PT 100 sensor defective Check PT 100 sensor
TAH OIL FEED

Regulating valve / Feed capacity
Setting TAH / Switching stages electr.
Temp. regulator def./
PT 100 sensor
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.6 Ejection Monitoring Alarm #07

No. Status PLC
X YY D 20
EJECTION MONITORING Eject. current < Offset

• Operating water valve V3 does not Check function bowl hydraulics with
open valve V3
• Connector on valve V3 loose Check connector on V3
• Offset setting for discharge current Check offset setting
too high
• Water quantity at V3 too low Check water quantity
• Setting of monitoring time for timer Check timer 28
28 is too short
• Current evaluation defective Check current converter electrically
• Pre-strainer at V3 dirty Check pre-strainer
• Clutch shoes worn or oily Check clutch shoes
EJECTION MONITORING
Function of bowl / Hydraulics with V3
Connector valve V3 / Current offset setting/
Water quantity / TIMER 28
Current converter / Pre-strainer
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.7 LAHH Sludge Tank Alarm #08

No. Status PLC
X YY D 20
LAHH SLUDGE TANK Sludge tank – full Separation - Stop

• Sludge pump not functioning Check sludge pump
• Bowl is open Check bowl hydraulics
• Oil overflow due to excessive clean Check valves in the clean oil line and
oil discharge pressure setting V7
• Closing water pulse T06 too long Check closing water pulse T06
• Polyamide sealing ring defective Check polyamide sealing ring
• Sealing rings in the bowl defective Check sealing rings
• Level switch LSHH dirty or defective Check level switch LSHH
LAHH SLUDGE TANK

Alarm #08 Please check:
Sludge pump / Bowl hydraulics
Valves in the clean oil line
Setting V7 / Closing water pulse
Polyamide sealing ring / Switch LSHH
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.8 Feed Pump Fault Alarm #09

No. Status PLC
X YY D 20
FEED PUMP FAULT Motor protection Separation - Stop

• Pump overloaded Check protection switch current of mo-
tor circuit breaker
• Pump mechanically blocked Check pump
• Valves in the feed line closed Check valves
• Feed temperature Check feed temperature
• Filter in feed line dirty Check filter
• Electrical connections wrong Check electrical connections and ca-
bling
FEED PUMP FAULT

Protection switch / Current consumption/
Pump / Valves / Feed temperature / Filter
Electr. connections / Cabling
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.9 Sludge Pump Fault Alarm #10

No. Status PLC
X YY D 20
SLUDGE PUMP FAULT Program - Stop

• Pump overloaded Check protection switch and current of
circuit breaker
• Pump mechanically blocked Check pump
• Valves in the discharge line closed Check valves
• Pipe work dirty Check pipe work
• Electrical connections wrong Check electrical connections and ca-
bling
SLUDGE PUMP FAULT

Protection switch / Current consumption /
Pump / Valves / Pipe work
Electrical connection / Cabling
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.10 Min. Separating Time Alarm #14

No. Status PLC
X YY D 20
MIN. SEPARATING TIME < 10 min. Separation - Stop

• Pressure sensor PSL2 not con- Check switching function of pressure
nected, dirty or defective sensor PSL2
• Alarm bridging time T11 too short Check T11
• Setting on pressure sensor PSL2 Check setting on pressure sensor
too high PSL2
• Water or solids content in the bowl Pre-dewater oil and/or check solids con-
too high tent
• To much filling water Check filling water quantity
• With HFO and parallel operation, Remove screws from separating disk
screws in the separating disk in-
stalled
• Filling water valve V2 not tight Check filling water valve V2
• Orifice in centripetal pump chamber Check orifice
cover plugged
MIN. SEPARATING TIME

Pressure sensor PSL2 / TIMER 11
Setting PSL2 / Water content
Valve V2 / Screws in separating disk
with HFO operation
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.11 WMS system Fault Alarm #15

No. Status PLC
X YY D 20
WMS SYSTEM FAULT Too much water Separation - Stop

• Water content in oil feed too high Check oil feed
• Too much filling water setting of T02 Check T02
too long
• Filling water valve V2 leaking Check filling water valve V2
• Setting of timer T22 too short Check setting In an emergency, extend
T22 during this phase
WMS SYSTEM FAULT

Water content in oil feed
Filling water quantity / Setting T02
Valve V2 / Setting T22
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.12 No Water Seal Alarm #16

No. Status PLC
X YY D 20
NO WATER SEAL during TIMER 35 Separation - Stop

• Clean oil discharge pressure too Check clean oil discharge pressure
high, valve V7 closed too far
• Filling water valve V2 does not open Check function V2
• Filling water quantity too low, e.g. Check filling water quantity
other consumers at same time
• Filling water valve V2 or filters dirty Check valve V2 and filters
• Water pressure for hydraulics too Check water pressure with open valve
high or T06 too long and T06
• Shift of separating zone – oil Check temperature and setting of TAL
temperature too low
• Wrong sensing centripetal pump in- Check parts in accordance with operat-
stalled ing instruction
• Pressure sensor PSL2 bridged or Check setting PSL2
set to 0
NO WATER SEAL
Clean oil discharge pressure
Function V2 / Filling water quantity
Valve V2 and filter / Water pressure
TIMER T06 / Setting TAL / Setting PSL2
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.13 PSL 1 Monitoring Alarm #17

No. Status PLC
X YY D 20
PSL 1 MONITORING clean oil discharge Separation – Stop

• No pressure drop on PSL1 during Check switching function
discharge
• PSL 1 is dirty, sticks or is defective Clean and check PSL1
• Setting of PAL 1 is too low Check setting PAL1
• No ejection and ejection monitoring Check bowl hydraulics and ejection
has not responded monitoring
• Back pressure in system too high Check discharge pressure
In an emergency, deselect function
PSL1 MONITORING
Switching function PSL1 / PSL1 dirty
Setpoint PAL1 / Bowl hydraulics /
Ejection monitoring / Discharge pressure
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.14 Bowl Monitoring Alarm #18

No. Status PLC
X YY D 20
BOWL MONITORING Current > Offset during TIMER 06
x and yy = system
data

• T06 closing water pulse too long, Check T06
bowl has opened
• Current offset bowl monitoring too Check current offset
low
• Frequency of main power supply not Check frequency of main power supply
stable
• Water pressure for hydraulics during Check water pressure with open valve
T06 too high, bowl has opened V3
• Valve V3 is dirty, sticks, stays open Check valve V3
for too long
• New clutch shoes installed Check current value
• New belt installed Check current value
In emergency, deselect function
BOWL MONITORING
TIMER T06 / Current offset
Frequency power supply
Water pressure for hydraulic
Function V3
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.15 Separator Motor Off Alarm #19

No. Status PLC
X YY D 20
SEP. MOTOR OFF Sep. in circulation T 39 expired M. off

• Separator running in circulation T39 Press program start before expiry of T39
has expired
• Setting of T39 too short Check T39
In an emergency, deselect function
SEPARATOR MOTOR OFF

Alarm19# Please check:
TIMER 39 expired
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.16 SMS Sensor Fault Alarm #20

No. Status PLC
X YY D 20
SMS SENSOR FAULT during SMS CHECK during TIMER 44

• PSL2 no pressure signal Check setting PAL2
• Filling water valve V2 no function Check function V2
• T44 too short Check T44
• Sludge holding space blocking pres- Clean bowl, check drill hole in centripe-
sure sensor line to PSL2 tal pump chamber cover
• Bowl not closed Check bowl hydraulics
• Insufficient water quantity during T44 Check water quantity
(Timer T60 – T62)
• Pressure sensor PSL2 defective Check pressure sensor PSL2
• Wrong switching point on PSL2 Check switching point
SMS SENSOR FAULT

Setpoint PAL2 / Function V2
Timer 44 / Solids holding space
Orifice in centripetal pump chamber
cover / Bowl hydraulics / Function PSL2
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.17 WMS Sensor Fault Alarm #21

No. Status PLC
X YY D 20
WMS SENSOR FAULT during WMS CHECK during TIMER 45

• WMS sensor dirty Check WMS sensor
• WMS sensor malfunction Check WMS sensor
• Water discharge valve V6 malfunc- Check function V6 or V5
tion
• Insufficient water during T45 Check water quantity
• T 02 too short (HFO) Check T02 (HFO)
WMS SENSOR FAULT

WMS sensor is dirty / Function WMS
sensor / Function V6 or V5
Water quantity Timer 45
Timer 02 (HFO)
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.18 Excessive Running Time Of Sludge Pump Alarm #22

No. Status PLC
X YY D 20
EXCESSIVE RUNNING TIME OF SLUDGE PUMP In TR3 h.

• Setting of TR2 time recording too Check TR2 time recording
short
• Bowl leakage Check bowl function/hydraulics
• Excessive water content in feed Dewater product upstream of the sepa-
rator
• Light oil overflow because clean oil Check setting of clean oil discharge
discharge pressure too high pressure
• Capacity of sludge pumps too low Check pump function
TR1 = Time record of WMS water sensor during HFO operation, TR1 will
be deleted when TR3 has expired.
TR2 = Time record of sludge pump operation, TR2 will be deleted when
TR3 has expired.
TR3 = Time counter factory setting 24 h
EXCESSIVE RUN.TIME OF SLUDGE PUMP

TR2 time recording / Bowl function
Bowl leakage
Water content in Oil
Pump function
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.19 WMS Activated Too Often Alarm #23

No. Status PLC
X YY D 20
WMS ACTIVATED TOO OFTEN

• Setting of TR1 time recording too Check TR1 time recording
short
• Water content in oil too high Dewater oil feed of the separator
• Valve V2 not tight Check V2
TR1 = Time record of WMS water sensor during HFO operation, TR1 will
be deleted when TR3 has expired.
TR2 = Time record of sludge pump operation, TR2 will be deleted when
TR3.has expired.
TR3 = Time counter factory setting 24 h
WMS ACTIVATED TOO OFTEN

TR1 time recording
Valve V2 is not tight
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.20 SMS Sensor Active Alarm #24

No. Status PLC
X YY D 20
SMS SENSOR ACTIVE in Idle run

• Pressure sensor PSL2 activated dur- Check pressure sensor PSL2
ing idle run conditions?
• Valve V2 not tight Check V2
• Product valve V1 does not close Check valve V1
properly
• Non-return valve at V7 open, prod- Close clean oil discharge valve V7 un-
uct flows back into the bowl der no load
SMS SENSOR ACTIVE IN IDLE RUN

Pressure sensor PSL2 / Valve V2 is
not tight/ Valve V1 closes not properly
Oil flows back into the bowl
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.21 Maintenance Alarm #27

No. Status PLC
X YY D 20
MAINTENANCE required see manual

• Operating hours have reached Carry out maintenance according man-
ual
• 4000 ; 8000 Use set of spare parts
• 12000 ; 16000 Order spare parts from Westfalia Min-
eraloil Systems
• or multiple hours Order service from Westfalia Mineraloil
Systems
MAINTENANCE required
Operating hours have reached
4000; 8000; 12000; 16000 hours
or multiple / Carry out maintenance
according manual
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.22 Warning Water content >0.5% Warning Alarm #28

No. Status PLC
X YY D 20
WARNING WATER CONTENT >0. 5%

• Water content in oil higher than Dewater oil and check reason
0.5% (by volume)
• T47 too long not consistent timer list Check setting T47
• Filling water valve V2 not tight Check valve V2
WARNING WATER CONTENT >0.5%

Setting TIMER 47 and feed capacity
Valve V2 is not tight
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.23 TAL OIL Feed Warning Alarm #31
No. Status PLC

X YY D 20
TAL OIL FEED Temp. < min WARNING

• Oil too cold before pre-heater Check settling tank temperature
(Settling tank applies to HFO only)
• Setting TAL has been set too high Check setting TAL
• Temperature of heating medium Check temperature of heating medium
is too low
stage switched
• Pre-heater dirty Check pre-heater
• PT100 sensor defective Check sensor
TAL OIL FEED

Settling tank temp. / Feed capacity
Setting TAL / Temp. of heating medium
Temp. regulator def. / Switching stages el.
pre-heater / PT 100 sensor
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.24 TAH OIL Feed Warning Alarm #32
No. Status PLC

X YY D 20
TAH OIL FEED Temp. > max WARNING

• Oil too hot Check regulating valve
• Feed capacity too low Check feed capacity
• Setting TAH too low Check setting TAH
stage switched
• PT100 sensor defective Check PT 100 sensor
TAH OIL FEED

Regulating valve / Feed capacity
Setting TAH / Switching stages el.
Temp. regulator def.
PT 100 sensor
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.25 Ejection Monitoring Alarm #33

No. Status PLC
X YY D 20
EJECTION MONITORING Eject. speed < Offset Sep. - Stop

• Operating water valve V3 does not Check function bowl hydraulics with
open valve V3
• Connector on valve V3 loose Check connector on V3
• Seep offset ejection monitoring too Check speed offset
high
• Water quantity at V3 too low Check water quantity
• Setting of monitoring time for timer Check timer 28
28 is too short
• Speed pick-up sensor defective Check speed pick -up sensor electri-
cally
• Pre-strainer at V3 dirty Check pre-strainer
Alarm#33 only active, if speed pick-up is installed!
EJECTION MONITORING
Function of bowl / Hydraulics with V3
Connector valve V3 / Speed offset eject.
Water quantity / TIMER 28 / Speed pick- up
defective / Pre-strainer
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.26 Bowl Monitoring speed Alarm #34
No. Status PLC

X YY D 20
BOWL MONITORING Speed drop > Offset during T 06
x and yy = system
data

• T06 closing water pulse too long, Check T06
bowl has opened
• Water pressure for hydraulics during Check water pressure with open valve
T06 too high, bowl has opened V3
• Speed offset bowl monitoring too Check speed offset
low
• Valve V3 is dirty, sticks, stays open Check valve V3
for too long
• Speed pick- up sensor defective Check speed pick- up sensor electrically

BOWL MONITORING
TIMER T06 / Water pressure
for hydraulic / Speed offset
bowl monitoring / Function V3
Speed pick- up defective
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.27 Motor Start monitoring Alarm #35

No. Status PLC
X YY D 20
SEPATATOR-START monitoring during TIMER 10
x and yy = system
data

• T10 separator start time too short Check T10
• Brake not unfastened Check brake
• Drive belt worn or oily Check drive belt
• Speed setting for sensor operation- Check speed setting

speed too high
• Speed pick- up sensor defective Check speed pick- up sensor electrically
SPEARATOR- START
TIMER T10 / Brake unfastened / Clutch
shoes oily / Drive belt oily / Speed setting
of operation speed / Speed pick-up defective
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.28 Belt monitoring Alarm #36

No. Status PLC
X YY D 20
BELT MONITORING Drive belt broken during start up

• Drive belt defect Check drive belt
• Motor defect Check motor electrically
• Speed pick- up sensor defective Check speed pick- up sensor electri-
cally
BELT MONITORING
Drive belt / Motor defect electrically
Clutch shoes worn or oily
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.29 Max.- speed monitoring Alarm #37

No. Status PLC
X YY D 20
MAX.- SPEED MONITORING during operation

• Actual speed higher than permissi- Check speed
ble speed for operation
• Speed setting for maximum speed Check maximum speed setting
too low
• Frequency unstable Check frequency
• Drive assembly (50 or 60 Hz) of Check separator configuration for fre-
separator does not fit to existing frequency against existing frequency at
quency at site site
• Speed pick- up sensor defective Check speed pick –up sensor electri-
cally
MAX.- SPEED MONITORING

Speed in operation / Max.- Speed setting/
Frequency unstable / Sep. configuration
frequency opposite to frequency at site
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.30 Min.- speed monitoring Alarm #38

No. Status PLC
X YY D 20
MIN.- SPEED MONITORING during operation

• Actual speed lower than permissible Check speed
speed for operation
• Speed setting for minimum speed Check minimum speed setting
too high
• Frequency unstable Check frequency
• Drive assembly (50 or 60 Hz) of Check separator configuration for fre-
separator does not fit to existing frequency against existing frequency at
quency at site site
• Speed pick- up sensor defective Check speed pick –up sensor electri-
cally
MIN.- SPEED MONITORING

Speed in operation / Max.- Speed setting
Frequency unstable / Sep. configuration
frequency opposite to frequency at site
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.31 PT 1 MONITORING Alarm #39

No. Status PLC
X YY D 20
PT 1 MONITORING clean oil discharge Separation – Stop

• No pressure drop on PT 1 during Check switching function
discharge
• PT 1 is dirty, sticks or is defective Clean and check PT 1
• Setting of PAL 1 is too low Check setting PAL 1
• No ejection and ejection monitoring Check bowl hydraulics and ejection
has not responded monitoring
• Back pressure in system too high Check discharge pressure
Alarm#39 only active, if pressure transmitter is installed!
PT 1 MONITORING
Switching function PT 1
PT 1 dirty / Setpoint PAL 1
Bowl hydraulics / Ejection
monitoring / Discharge pressure
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.32 No Water Seal Alarm #40

No. Status PLC
X YY D 20
NO WATER SEAL during TIMER 35 Separation - Stop

• Clean oil discharge pressure too Check clean oil discharge pressure
high, valve V7 closed too far
• Filling water valve V2 does not open Check function V2
• Filling water quantity too low, e.g. Check filling water quantity
other consumers at same time
• Filling water valve V2 or filters dirty Check valve V2 and filters
• Water pressure for hydraulics too Check water pressure with open valve
high or T06 too long and T06
• Shift of separating zone – oil Check temperature and setting of TAL
temperature too low
• Wrong sensing centripetal pump in- Check parts in accordance with operat-
stalled ing instruction
• Pressure sensor PT 2 bridged or set Check setting PT 2
to 0
NO WATER SEAL
Clean oil discharge pressure
Function V2 / Filling water quantity
Valve V2 and filter / Water pressure
TIMER T06 / Setting TAL / Setting PT 2
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.33 Min. Separating Time Alarm #41

No. Status PLC
X YY D 20
MIN. SEPARATING TIME < 10 min. Separation - Stop

• Pressure sensor PT 2 not con- Check switching function of pressure
nected, dirty or defective sensor PT 2
• Alarm bridging time T11 too short Check T11
• Setting PT 2 too high Check setting on pressure sensor PT 2
• Water or solids content in the bowl Pre-dewater oil and/or check solids con-
too high tent
• To much filling water Check filling water quantity
• With HFO and parallel operation, Remove screws from separating disk
screws in the separating disk in-
stalled
• Filling water valve V2 not tight Check filling water valve V2
• Orifice in centripetal pump chamber Check orifice
cover plugged
MIN. SEPARATING TIME

Pressure sensor PT 2 / TIMER 11
Setting PAL 2 / Water content
Valve V2 / Screws in separating disk
with HFO operation
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.34 SMS Sensor Fault Alarm #42

No. Status PLC
X YY D 20
SMS SENSOR FAULT during SMS Check during TIMER 44

• PT 2 no pressure signal Check setting PT 2
• Filling water valve V2 no function Check function V2
• Sludge holding space blocking pres- Clean bowl, check drill hole in centripe-
sure sensor line to PT 2 tal pump chamber lid
• Bowl not closed Check bowl hydraulics
• Insufficient water quantity during T44 Check water quantity
(Timer T60 – T62)
• Pressure sensor PT 2 defective Check pressure sensor
• Wrong switching point on PT 2 Check switching point
SMS SENSOR FAULT

Setting PAL 2 / Function V2
Timer 44 / Solids holding space
Orifice in centripetal pump chamber
cover / Bowl hydraulics / Function PT 2
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.35 SMS Sensor Active Alarm #43

No. Status PLC
X YY D 20
SMS SENSOR ACTIVE in Idle run

• Pressure sensor PT 2 activated dur- Check pressure sensor PT 2
ing idle run conditions?
• Filling water valve V2 leaking Check V2
• Product valve V1 does not close Check valve V1
properly
• Non-return valve at V7 open, prod- Close pure oil discharge valve V7 under
uct flows back into the bowl no load
SMS SENSOR ACTIVE IN IDLE RUN

Pressure sensor PT 2 / Valve V2 is
not tight/ Valve V1 closes not
properly / Oil flows back into the bowl
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.36 PAL 1 Clean Oil Discharge Alarm #44

No. Status PLC
X YY D 20
PAL 1 CLEAN OIL DISCHARGE Pressure < setting

• Clean oil discharge valve V7 Check valve setting V7
opened too wide
• Feed capacity reduced Check feed capacity
• Setting PT 1 for PAL 1 too high Check setting PT 1 for PAL 1
see also PAH 1 alarm
• Water pressure for hydraulics too Check water pressure with opened
high during T06, bowl has opened valve V3
• Safety pulse T06 too long, bowl has Check TIMER 06
opened
• Feed pump failure Check feed pump
• FU speed too low Check pump speed
• Feed valve V1 in circulation position Check compressed air and signal out-
put for solenoid valve on V1
• Breakover to water side Check quantity of filling water
• Direction of rotation of pump incor- Check direction of rotation
rect
• Bowl gaskets not sealed Check and where necessary replace
gaskets
• T07 alarm delay too short Check whether T07 expires before
pressure builds up
• T11 alarm bridging too short Check TIMER 11 alarm bridging
FU = Frequency transformer
PAL 1 CLEAN OIL DISCHARGE

Setting PT1 for PAL / Water pressure for
opened valve V3 / TIMER 06 /T07 alarm
delay / Quantity of water / Bowl not sealed
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.37 PAH 1 Clean Oil Discharge Alarm #45

No. Status PLC
X YY D 20
PAH 1 CLEAN OIL DISCHARGE Pressure > setting

• Clean oil discharge valve V7 closed Check valve setting V7
too far
• Setting PT1 for PAH1 too low Check setting PT 1 for PAH 1
• T07 alarm delay too short Check T07

• T11 alarm bridging too short Check T11 alarm bridging
• Oil temperature too low Check temperature in oil feed
PAH 1 CLEAN OIL DISCHAGE

Setting PT1 for PAH 1 / T07 alarm delay
T11 alarm bridging /
Temperature oil feed
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
4.38 EMERGENCY STOP Alarm #46

No. Status PLC
X YY D 20
EMERGENCY STOP

• Emergency Stop Button was Check reason for pushing Emergency
pushed. Stop button.
EMERGENY STOP
Emergency Button
Press ESC then ACK
8555-9201-100 / 0806
Westfalia Separator
8555-9201-100 / 0806
Westfalia Separator
5 Alarm simulation and test
8555-9201-100 / 0806
Westfalia Separator
5.1 Alarms #01 - #18

SIMULATION AND TESTS OF VARIOUS ALARMS
Alarm display Status Mechanical Electrical Action
MOTOR PROTECTION Control Not possible Disconnect PTC sensor Separation stop
Alarm#01 active V1 in circulation
Common alarm
Motor off
PAL1 CLEAN OIL Separation Open clean oil discharge Disconnect cable head on Separation stop
DISCHARGE valve V7 pressure sensor PSL1 V1 in circulation
Alarm#02 Common alarm
Ejection
PAH1 CLEAN OIL Separation Close clean oil discharge Disconnect cable head on Separation stop
DISCHARGE valve V7 pressure sensor PSH1 V1 in circulation
Ejection
TAL OIL FEED Separation Not possible Set setting higher than the Separation stop
Alarm#05 current temperature V1 in circulation
Common alarm
Ejection
TAH OIL FEED Separation Not possible Set setting lower than the cur- Separation stop
Alarm#06 rent temperature V1 in circulation
Common alarm
Ejection
EJECTION MONITORING Ejection Close manual ball valve Disconnect cable head of V3 Separation stop
Eject. Current which is in front of V3 shortly or increase offset Ejection V1 in circulation
Alarm#07 before and during discharge current during discharge cy- Common alarm
cycle T04. cle T04.
LAHH SLUDGE TANK Control Immerse or dampen sensor Disconnect cable head of Separation stop
Alarm#08 Active LSHH. LSHH Sensor V1 in circulation
Common alarm
Ejection
FEED PUMP FAULT Control Not possible Trigger motor protection Separation stop
Alarm#09 Active switch V1 in circulation
Common alarm
Pump motor off
SLUDGE PUMP FAULT Control Not possible Trigger motor protection Separation stop
Alarm#10 Active switch V1 in circulation
Common alarm
Pump motor off
MIN. SEPARATING TIME Separation Not possible. Disconnect cable head on Separation stop
Alarm#14 pressure sensor PSL2 during V1 in circulation
T21. Common alarm
Ejection
WMS SYSTEM FAULT Separation Open valve V2 to add water Bridge WMS Sensor and set Separation stop
Alarm#15 into bowl until Timer 22 is pressure sensor PSL2 switch- V1 in circulation
elapsed. ing point to 0 or bridge. Common alarm
Ejection
NO WATER SEAL Separation Reduce T34 and T35 to 5 Bridge pressure sensor PSL2 Separation stop
Alarm#16 sec. and close hand valve and disconnect cable of WMS V1 in circulation
before V2 during T02. sensor. Common alarm
Ejection
PSL 1 MONITORING Ejection Not possible. Bridge pressure sensor PSL1 Separation stop
Alarm#17 while ejection sequence is V1 in circulation
running. Common alarm
BOWL MONITORING Separation Not possible. Extend T06 during separation Common alarm
Current > Offset and shorten T14 to 300sec.!
Alarm#18 Wait until T14 is elapsed and
Alarm appears.
for a simulation, the function must be activated and must be valid for the product
After the simulation, all changes must be reset to the initial conditions!!!!
8555-9201-100 / 0806
Westfalia Separator
5.2 Alarms #19 - #37

SEP. MOTOR OFF Circulation Not possible. Set TIMER 39 to 10 seconds Common alarm
Alarm#19 and push program stop but- Motor off
ton.
SMS SENSOR FAULT Sensor Close hand valve at V2 Disconnect cable head on Common alarm
Alarm#20 Check while test is running. pressure sensor PSL2 while Ejection
test is running.
WMS SENSOR FAULT Sensor Not possible. Disconnect cable head on Common alarm
Alarm#21 Check WMS sensor while test is run- Ejection
ning.
EXCESSIVE RUNNING Control Ac- Set TR2 to 1 minute and Set TR2 to 1 minute Common alarm
TIME OF SLUDGE PUMP tive immerse or dampen LSH Trigger test function with
Alarm#22 Sensor to start sludge pump magnet at test point of LSH
until Alarm appears. sensor until Alarm appears.
WMS ACTIVATED TOO Separation Set T22 to 300sec. and TR1 Set T22 to 300sec., TR1 to 1 Common alarm
OFTEN to 1 minute and open valve minute and bridge WMS sen-
Alarm#23 V2 to add water into bowl sor until Alarm appears.
until Alarm appears.
SMS SENSOR ACTIVE Circulation Open valve V2 until pres- Bridge pressure sensor PSL2 Message in the
in idle mode sure increase on pressure during idle run. display
Alarm#24 sensor PSL2 during idle Common alarm
run. Ejection
Maintenance Separation Not possible. Set value to actual value plus Message in the
Alarm#27 1hour and wait 1hour. display
WARNING After 15 Set counter 5 to 1 and T47 Set counter 5 to 1 and bridge Message in the
WATER CONTENT >0.5% min. of to 60sec.than open valve V2 pressure sensor PSL2 or set display
Alarm#28 Separation for 10sec. to add water into optional PT2 to 0 and 1 in V6 opens
bowl until warning appears. short intervals during T47 for
minimum 2 times, so that
warning appears.
TAL OIL FEED Separation Not possible. Set setting higher than the Message in the
WARNING current temperature display
Alarm#31
TAH OIL FEED Separation Not possible. Set setting lower than the cur- Message in the
WARNING rent temperature display
Alarm#32
EJECTION MONITORING Ejection Close manual ball valve Disconnect cable head of V3 Separation stop
Eject. Speed which is in front of V3 or increase offset Ejection V1 in circulation
Alarm#33 shortly before and during speed during discharge cycle Common alarm
discharge cycle T04. T04.
BOWL MONITORING Separation Not possible. Extend T06 during separation Common alarm
Speed drop > Offset and shorten T14 to 300sec.!
Alarm#34 Wait until T14 is elapsed and
Alarm appears.
SEPARATOR-START Separator Set Timer 10 to 10 sec. and Set setting for min. speed Motor off
Alarm#35 Motor Start press motor start button. higher than the normal operat- Message in the
ing speed. display
Common alarm
BELT MONITORING Separator Not possible. Disconnect speed pick-up Motor off
Alarm#36 Motor Start sensor and press motor start Message in the
button. display
Common alarm
MAX.SPEED Separator Not possible. Set setting for Max. Speed Motor off
MONITORING Motor Start lower than normal operating Message in the
Alarm#37 and Separa- speed, during start up or dur- display
tion ing operation. Common alarm
for a simulation, the function must be activated and must be valid for the product
8555-9201-100 / 0806
Westfalia Separator
5.3 Alarms #38 - #46

MIN.SPEED Separator Not possible. Set setting for Min. Speed higher Motor off
MONITORING Motor Start than normal operating speed, Message in the
Alarm#38 and Separa- during start up or during display
tion operation. Common alarm
PT 1 MONITORING Ejection Not possible. Set pressure sensor PT1 switch- Separation stop
Alarm#39 ing point to 0 while ejection se- V1 in circulation
quence is running. Common alarm
NO WATER SEAL Separation Reduce T34 and T35 to 5 Set pressure sensor PT2 to 0 and Separation stop
Alarm#40 sec. and close hand disconnect cable of WMS sensor. V1 in circulation
valve before V2 during Common alarm
T02. Ejection
MIN. SEPARATING TIME Separation Not possible. Disconnect cable head on pres- Separation stop
Alarm#41 sure sensor PT2 during T21. V1 in circulation
Common alarm
Ejection
SMS SENSOR FAULT Sensor Close hand valve at V2 Disconnect cable head on pres- Common alarm
Alarm#42 Check while test is running. sure sensor PT2 while test is run- Ejection
ning.
SMS SENSOR ACTIVE Circulation Open valve V2 until Set pressure sensor PT2 to 0 dur- Message in the
in idle mode pressure increase on ing idle run. display
Alarm#43 pressure sensor PT2 Common alarm
during idle run. Ejection
PAL1 CLEAN OIL Separation Open clean oil dis- Disconnect cable head on pres- Separation stop
DISCHARGE charge valve V7 sure sensor PT1 V1 in circulation
Ejection
PAH1 CLEAN OIL Separation Close clean oil dis- Set pressure sensor PT1 switch- Separation stop
DISCHARGE charge valve V7 ing point to a lower value than the V1 in circulation
Alarm#45 current value. Common alarm
Ejection
Safety Test without Alarm!

EMERGENCY STOP Control Not possible. Push emergency button. All electric compo-
Alarm#46 Active nents are shut
down like Motors,
Control Units, etc.!
For a simulation, the function must be activated and must be valid for the product
8555-9201-100 / 0806
Westfalia Separator
6 Ejection / Bowl monitoring
8555-9201-100 / 0806
Westfalia Separator
6.1 General description
Function Terminal Value

Sep. motor current: AI 0.0
Due to the differing motor power ratings, the current trans-
former ratio can be adapted if external motor starters are
used so the control unit display will show the correct motor
current of the separator.
The desired ratio can be selected from the options 10/1A,
25/1A, 50/1A and 100/1A.
Measuring principle
The transformer signal of 1 A max. on the transformer sec-
ondary side is connected with a measuring transducer in
the control unit cabinet by a two-wire circuit and trans-
formed there into a 4-20 mA signal which is connected to
the D20 control unit as an analogue input and then shown
on the process display.
The signal continuously shows the current separator cur-
rent value and is used as a parameter for ejection monitor-
ing.
Measuring principle of ejection monitoring:
Just before ejection, the operating current is read in and the
offset value is added. After ejection within the time range of
timer 28, the current must rise by this value. The offset
value is pre-adjusted on this side.
Example:
The current operating current is 10 A before opening the
control water valve. Ejection is by the control water valve,
with the current usually rising to e.g. 13 A. This offset value
of 3 A minus a tolerance value of e.g. 1 A is entered as a
monitoring value. (13A ejection current minus 1A tolerance
minus operating current prior to opening of control water
valve results in a setting value of 2A to be entered in line 1
of the display.)
Setpoint ejection monitoring: AI 0.0
When in separation operation, start a total ejection with the
start key and observe the ejection current in the corre-
sponding display. The ejection current normally is higher
than the nominal current in the separating program. Enter
the difference between the ejection current and the
separating current (e.g. 2.0 A) as offset value.
Ejection monitoring is not operative when 0.0 A was en-
tered as offset value. However, this should be done in ex-
ceptional cases only.
Transformer setting: 1:10
If the separator motor starter has been provided by the cus- 1:25
tomer, the ratio of the necessary current transformer can be
adapted in this setting mode. 1:50
1:100
8555-9201-100 / 0806
Westfalia Separator
6.1 Graphic description
Function Terminal Value

Bowl/operating current monitoring: AI 0.0
In the open field, select the desired format ON or
OFF and confirm with ENTER. During bowl monitor-
ing, the cyclic closing water pulse for the bowl hy-
draulics is monitored, i.e. if the closing water quantity
is too high, the bowl is opened which in turn causes
the current to rise and is controlled as follows: the
current separator operating current is measured and
saved 3 seconds before feeding the closing water
and 3 seconds after feeding the closing water, this
measurement is repeated and compared with the
previous current value. If the deviation is > 1 A, an
alarm is generated, but separation is not interrupted.
1: separator motor start
2: feed valve V1 open: sepa-

ration
3: feed valve V1 closed for

ejection
4: operating water valve V3

open for T04: ejection

ration
1: separator motor start

ration

open for T06: safety water
impuls

closed: separation
5: feed valve V1 closed:

ejection
8555-9201-100 / 0806
Westfalia Separator
6.2 General description Speed monitoring with speed pick-up
The motor start, bowl function during safety water impulse and the ejection are monitored by speed
pick-up!
1. During start up of the separator motor, the release for program start is given when preset speed value for
minimum operation speed is reached. The start up is monitored by Timer 10 separator start. If start up
takes too long, alarm “SEPARATOR START monitoring” #35 will be triggered.
2. A speed drop after ejection T04 will be compared with preset speed value for ejection monitoring. If
speed did not drop down enough, alarm “EJECTION MONITORING Eject. speed > Setpoint” #33 will be
triggered. Separation stops.
3. If bowl monitoring is activated, a speed drop after closing water impulse T06 will be compared with preset
speed value for bowl monitoring. If speed drops down too much, alarm “Bowl monitoring speed drop too
high during TIMER 06” #34, will be triggered. Separation program goes on.
8555-9201-100 / 0806
Westfalia Separator
8555-9201-100 / 0806
Westfalia Separator
8555-9201-100 / 0806
Westfalia Separator
8555-9201-100 / 0806
Westfalia Separator
Westfalia Separator Mineraloil Systems GmbH ● Werner-Habig-Straße 1 ● D-59302 Oelde (F.R. Germany)
Tel.: +49 (0) 25 22/77-0 ● Fax: +49 (0) 25 22/77-23 94 ●
http://www.westfalia-separator.com/● mailto:info@gea-westfalia.de
5 Separator
Separator
5.1 OSE Separator – Instruction Manual

OSE Separator – Betriebsanleitung
OSE 40-0196-067
Parts Catalogue
Ersatzteilkatalog
Parts Catalogue
Ersatzteilkatalog
Parts Catalogue
Ersatzteilkatalog
Parts Catalogue
Ersatzteilkatalog
Parts Catalogue
Ersatzteilkatalog
Parts Catalogue
Ersatzteilkatalog
5.2 Induction Motor
Drehstrommotor

Instruction manual
Designation Mineral oil centrifuge with self-cleaning bowl
Type OSE 40-0196-067
No. 2063-9001-100
Edition 0509

2 2063-9001-100 / 0509
TRANSLATION OF ORIGINAL INSTRUCTION MANUAL

the documentation. They can be addressed to:
Werner-Habig-Straße 1 · D-59302 Oelde (Germany)
Tel.: +49 (0) 25 22 / 77-0 · Fax: +49 (0) 25 22 / 77-17 78

2063-9001-100 / 0509 3
GEA Westfalia Separator Systems GmbH

59302 Oelde, Germany
Type S/N:
Year of manufacture
-1
Max. admissible rated bowl speed in min
3
Max. admissible density in kg/dm of product
Heavy 3
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 2063-9001-100 / 0509
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.

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 accor-
dance with the rules and regulations of the VDE (Verein Deutscher
Elektrotechnik / Association of German Electrical Engineering) or of
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

2063-9001-100 / 0509 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 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.

6 2063-9001-100 / 0509
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
1.6 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 Standard dimensioned drawing of the separator ................................... 38

2.2 Section through separator ..................................................................... 40
2.3 General .................................................................................................. 41
2.4 OSE ...-0196-... ...................................................................................... 41
2.4.1 Separator with water content and sludge space monitoring system
(WMS and SMS) for lube oil treatment .................................................. 42
2.5 Main components of the separator ........................................................ 43
2.5.1 Centripetal pump ................................................................................... 45
2.5.2 Bowl ....................................................................................................... 46
2.5.3 Bowl hydraulics ...................................................................................... 47
2.5.4 Drive ....................................................................................................... 50
2.6 Supervisory equipment .......................................................................... 55
2.6.1 Pressure transmitter .............................................................................. 55
2.6.2 Water detector ....................................................................................... 56
2.6.3 Solenoid valve ....................................................................................... 58
2.6.4 Vibration monitoring (Option) ................................................................. 60
2.6.5 Speed monitoring ................................................................................... 61
2.7 Product feed and discharge lines .......................................................... 62
2.7.1 Throughput monitoring (Product feed line A)......................................... 62
2.7.2 Determining the throughput (Product feed line A) ................................. 63
2.7.3 Pressure monitoring (Product discharge line B) .................................... 64
2.8 Technical data ....................................................................................... 65
3 Operation 67
3.1 Technical information ............................................................................. 68

3.1.1 Separating with the unitrolplus system .................................................. 68

2063-9001-100 / 0509 7
3.1.2 General information on bowl ejection .................................................... 68

3.2 Before start-up ....................................................................................... 70
3.2.1 Before the first start-up – after maintenance and repair ........................ 70
3.2.2 Before every start-up ............................................................................. 72
3.3 Starting the separator ............................................................................ 73
3.4 Monitoring of operation .......................................................................... 74
3.5 Setting the separation time .................................................................... 76
3.5.1 Mathematical calculation ....................................................................... 76
3.6 Ejecting the bowl .................................................................................... 77
3.7 Shutting down the separator .................................................................. 78
3.8 Trouble shooting .................................................................................... 82
3.8.1 Troubleshooting the separator ............................................................... 82
3.8.2 Bowl faults.............................................................................................. 84
4 Installation - Maintenance - Repair 91
4.1 Installation of the separator ................................................................... 92

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 Valves and flow indicator ..................................................................... 103
4.2.1 Installing valves ................................................................................... 104
4.3 Maintenance and lubrication ................................................................ 105
4.3.1 Maintenance schedule ......................................................................... 105
4.3.2 Hoses and hose pipes ......................................................................... 112
4.3.3 Lubrication ........................................................................................... 113
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 Westfalia
Separator ............................................................................................. 119
4.4 Bowl ..................................................................................................... 120
4.4.1 Dismantling the bowl ............................................................................ 122
4.4.2 Cleaning the bowl ................................................................................ 142
4.4.3 Cleaning the frame .............................................................................. 143
4.4.4 Cleaning the strainer and the operating water feeding system ........... 143
4.4.5 Cleaning the motor .............................................................................. 144
4.4.6 Important instructions for assembling the bowl ................................... 145
4.4.7 Assembling bowl .................................................................................. 147
4.4.8 Replacing the polyamide gasket (bowl top) ......................................... 162
4.4.10 Reworking the sliding piston ................................................................ 171
4.5 Closing the hood .................................................................................. 172
4.6 Drive ..................................................................................................... 174
4.6.1 Important instructions for fitting and removing the drive ...................... 176
4.6.2 Removing the drive belt and spindle assembly ................................... 178
4.6.3 Dismantling the spindle assembly ....................................................... 183
4.6.4 Dismantling the centrifugal clutch ........................................................ 185
4.6.5 Fitting the spindle assembly ................................................................ 189
4.6.6 Fitting the centrifugal clutch ................................................................. 192
4.6.7 Replacing the neck bearing springs (neck bearing bridge) ................. 199
4.6.8 Fitting the motor ................................................................................... 202
4.7 Height adjustment ................................................................................ 207
4.7.1 Bowl height .......................................................................................... 207
4.7.2 Centripetal pump clearance ................................................................. 209
4.8 Final checks after assembling the separator ....................................... 211

8 2063-9001-100 / 0509
4.9 Before a long-term shut-down of the separator ................................... 211

4.9.1 Preserving the separator ..................................................................... 211
4.9.2 Preserving the motor ........................................................................... 212
4.10 Storage ................................................................................................ 213
4.10.1 After delivery ........................................................................................ 213
4.10.2 Separator ............................................................................................. 213
4.10.3 Control system ..................................................................................... 213
4.11 Before restarting .................................................................................. 214
4.12 Disposal ............................................................................................... 215
4.12.1 Gear and lubricating oils ...................................................................... 215
4.12.2 Cleaning liquids ................................................................................... 216
4.12.3 Separator ............................................................................................. 216
4.13 Standard tools ...................................................................................... 218
4.14 Special tools ........................................................................................ 220
5 Spare parts 223
5.1 Spare part requirements ...................................................................... 224

5.2 Guide to ordering spare parts .............................................................. 224

2063-9001-100 / 0509 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
1.6 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 2063-9001-100 / 0509
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
processed.
• in accordance with the method of application of the separator agreed with
Westfalia Separator. Refer to the data sheet and contractually agreements.
• 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 Westfalia Separator on the in-
tended 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!

2063-9001-100 / 0509 11
1.2 Non-compliance with the intended use

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
Non-compliance with intended use can result in severe damage to prop-

erty and persons!

12 2063-9001-100 / 0509
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.

2063-9001-100 / 0509 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 2063-9001-100 / 0509
Before carrying out work, dis-

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

ponents:
standstill.
Fig. 4 • Switch off all electrical appliances
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!
off”.
centrifuge has come to a standstill.
Fig. 6

2063-9001-100 / 0509 15
Frequency converter operation!

• When setting the frequency con-
verter, 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
local electric power company.
specialists).

16 2063-9001-100 / 0509
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 Westfalia Separator.
Different colour leads can be fitted if requested by the customer!

2063-9001-100 / 0509 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, whe-
reas the specifically lighter components are displaced towards the centre of the
bowl.
The high centrifugal force is produced by very high bowl speeds. On the one
hand, high bowl speeds signify high efficiency, while on the other hand, they
signify high material stressing of the separator.

18 2063-9001-100 / 0509
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!

who
ing.
The operator of the separator or separator plant

• must be sure that the personnel have read and understood the manuals nec-
essary to carry out their work.

2063-9001-100 / 0509 19

courses. You can obtain further information from Westfalia Separator or from
one of the authorized representatives.

Separator. The original spare parts are listed
in the spare parts catalog.
– safety risks,
– reduced availability of the separator and
Fig. 15 If a safety risk occurs when using non-original
ranty 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 2063-9001-100 / 0509
CAUTION:
• Some bowl parts may be pre-
assembled and balanced only by
specialists from Westfalia Separa-
tor or in workshops authorized by
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
Westfalia Separator must be con-
sulted.
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 an-
other.
• 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

2063-9001-100 / 0509 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
• Tighten the bowl lock ring securely:

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

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

ber lock ring securely (left-hand
thread).
CAUTION:
Fig. 25

22 2063-9001-100 / 0509
• Carefully fasten hood 1, feed and

discharge housing 2 and centripetal
pump 3.
Fig. 26
• Check if the machine is completely

assembled and properly installed.
Fig. 27

cian!
Separator.
Fig. 28

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

2063-9001-100 / 0509 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 2063-9001-100 / 0509
• 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

2063-9001-100 / 0509 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 2063-9001-100 / 0509
• 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”.
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

2063-9001-100 / 0509 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 2063-9001-100 / 0509
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
automatically.

off”.
Fig. 44

2063-9001-100 / 0509 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 in-
spected by our service engineers at regular intervals. These checks help to
maintain the operating safety and avoid unexpected downtime.

30 2063-9001-100 / 0509

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

2063-9001-100 / 0509 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 2063-9001-100 / 0509
• 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

2063-9001-100 / 0509 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 2063-9001-100 / 0509
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.

2063-9001-100 / 0509 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 2063-9001-100 / 0509
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!

2063-9001-100 / 0509 37
2 Machine description
2.1 Standard dimensioned drawing of the separator ................................... 38

2.2 Section through separator ..................................................................... 40
2.3 General .................................................................................................. 41
2.4 OSE ...-0196-... ...................................................................................... 41
(WMS and SMS) for lube oil treatment .................................................. 42
2.5 Main components of the separator ........................................................ 43
2.5.1 Centripetal pump ................................................................................... 45
2.5.2 Bowl ....................................................................................................... 46
2.5.3 Bowl hydraulics ...................................................................................... 47
2.5.4 Drive ....................................................................................................... 50
2.6 Supervisory equipment .......................................................................... 55
2.6.1 Pressure transmitter .............................................................................. 55
2.6.2 Water detector ....................................................................................... 56
2.6.3 Solenoid valve ....................................................................................... 58
2.6.4 Vibration monitoring (Option) ................................................................. 60
2.6.5 Speed monitoring ................................................................................... 61
2.7 Product feed and discharge lines .......................................................... 62
2.7.1 Throughput monitoring (Product feed line A)......................................... 62
2.7.2 Determining the throughput (Product feed line A) ................................. 63
2.7.3 Pressure monitoring (Product discharge line B) .................................... 64
2.8 Technical data ....................................................................................... 65

38 2063-9001-100 / 0509
2.1 Standard dimensioned drawing of the separator
• For further information see installation guidelines.
Pressure transmitter (product discharge)

Pressure transmitter (self-thinker)
2/2-way solenoid valve (water outlet)
2/2-way solenoid valve (circuit)
Water detector:
Center of gravaty
The complete bowl can then be Solids discharge

transported via the adjacent Water / operating water discharge
separators of the same type.
Filling, displacement and operating water supply
Product discharge
Water / operating water discharge
Product discharge
Solids discharge
These functional dimensions must be adhered to!

Discharge must not feed into public water system!
Fig. 57 Note project-specific dimensioned drawing!

2063-9001-100 / 0509 39
Min. lifting capacity of hoist: 500 kg

For maintenance and repair
Bowl, motor
Center of gravity
Connectors:
Product feed
Product discharge
Discharge via the centripetal pump installed in the separator Water discharge
Operating water discharge
Solids discharge
Filling, displacement and operating
water supply
Solenoid valve block

Filling, displacement and Klemmenkasten
operating water

Water detector:
Service side
The foundation must not contact the foundations of other units (e.g. auxiliary diesel en-
gines, pumps) in order to prevent damage to ball bearings.


40 2063-9001-100 / 0509
2.2 Section through separator
Fig. 59

2063-9001-100 / 0509 41
2.3 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.
2.4 OSE ...-0196-...

The OSE separator ...-0196-... with unitrolplus-System is equipped with a self-
cleaning disk bowl. It is used for the clarification and separation of lube oil.
The separator with unitrolplus-System has two built-in monitoring functions:
– WMS (water content monitoring system)
– SMS (sludge space monitoring system)

42 2063-9001-100 / 0509
(WMS and SMS) for lube oil treatment
The simultaneous water content and sludge space monitoring systems are used
for the continuous purification of lube oil.
Fig. 60 Example of monitoring
1 Dirty oil feed 11 Sensing liquid pump

2 Clean oil discharge 12 Centripetal pump (clean oil)
3 Displacement water 13 Separating disk
4 Pressure transmitter (clean oil) 14 Dirty water discharge
5 Water detector 15 Solids holding space
6 Pressure transmitter 16 Solids discharge
7 Solenoid valve circuit 17 Operating water discharge
8 Solenoid valve water discharge 18 Operating water feed
9 Partial flow 19 Solenoid valve block
10 Control and monitoring device 20 Throttle
The lube oil is conveyed to the separator via a separate pump.
The dirty oil feed occurs (1) through a closed line system.
Before separation begins, the sludge space (15) is filled with water (3).
The clean oil is discharged (2) under pressure by centripetal pump (12) via the
clean oil discharge.
The bowl is automatically opened and closed for desludging at full bowl speed
by means of a solenoid valve (19) in the operating water line.
During the separation process, solids and water are separated from the oil, wa-
ter is discharged by the sensing liquid pump (11) through the dirty water dis-
charge (14).
The sludge space (15) is periodically monitored. When blockage occurs as a re-
sult of increased solids accumulation, the pressure pulse on pressure transmit-
ter (6) is not given and an automatic ejection cycle is initiated via the control unit
(10).
The control and monitoring unit (10) ensures unmanned operation.

2063-9001-100 / 0509 43
2.5 Main components of the separator
Fig. 61
Pos. Designation Function

1 Handle connection • connects centripetal pump and hood.
piece • takes up the filling and displacement water
feed line.
2 Centripetal pump See section 2.5.1

Sensing liquid pump
3 Hood • covers the rotating bowl.
• holds the feed and discharges (see section
2.7).
4 Sensor block • mounted on the hood.

• is replaceable as a unit.
• includes the following parts:
– Pressure transmitter (product discharge
line) (see section 2.6.1:
– Pressure transmitter (unitrolplus-System –
SMS function) (see section 2.6.1)
– 2/2-way solenoid valve (water discharge)
(see section 2.6.3)
– 2/2-way solenoid valve (circulation) (see
section 2.6.3)
– Water detector (unitrolplus-System – SMS
function) (see section 2.6.2)
5 Bowl: See section 2.5.2

Bowl hydraulics See section 2.5.3
6 Frame • contains the drive parts.

• supports motor, bowl and hood.

44 2063-9001-100 / 0509

7 Sight glass allows oil-level check.
8 Sight glass for observation of the drive belt.
9 Brake • The run-down time of the bowl can be short-

ened by applying the brake (e.g. for servicing
and maintenance work). See section 2.8.
Applying the brake

• is not necessary in the case of a normal sepa-
rator shut-down (section 3.7).
• is ineffective if a drive belt is torn, defective or
has come off!
Be sure to observe the run-down time of 120
minutes until dismantling the separator! See
section 3.7.)
10 Solenoid valve block See section 2.5.5
11 Drive See section 2.5.4
12 Motor • accelerates the separator to the required

speed.
• is protected against overload during operation.

2063-9001-100 / 0509 45
2.5.1 Centripetal pump
Fig. 62
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.

46 2063-9001-100 / 0509
2.5.2 Bowl
Fig. 63

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 pro-
duces 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.

2063-9001-100 / 0509 47
2.5.3 Bowl hydraulics
A B
Fig. 64
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.

48 2063-9001-100 / 0509
Closing the bowl (separation)
A B
Fig. 65

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.

2063-9001-100 / 0509 49
Opening the bowl (ejection)
A B
Fig. 66

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.

50 2063-9001-100 / 0509
2.5.4 Drive
Fig. 67

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.

2063-9001-100 / 0509 51
2.5.5 Solenoid valve block

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. 68
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
The manual override can only be

actuated with a screwdriver!
1 closed
2 open
Fig. 69

52 2063-9001-100 / 0509
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

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. 70

2063-9001-100 / 0509 53
Technical data
IMPORTANT:
• Note the specifications on the nameplate of the solenoid valve block and
• the installation guidelines.
Part-No. see parts list

Operating principles 2/2-way solenoid valve
NC
Material: Gasket EPDM
Housing CuZn
Valves Coil size 32 mm
Nominal diameter
13 mm
(DN)
Operating voltage: 24 V DC
Rating 8 W (per valve)
Coupler socket with built-in electronics,
24 V DC, LED and free-wheeling diode
with fitted cable (1.5 m long)
Pressure Medium 0 to 10 bar
Control range 1 to 6 bar
Pressure setpoint 2 bar
with open valve
Temperature: Medium -10 to +80 °C (14 – 176 °F)
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.
CAUTION: Danger of injury through very hot separator parts!

When carrying out maintenance work, there is a danger of injury through hot
o
separator parts (separating temperatures of 70 to 100 C (158 – 212 °F)).
IMPORTANT:
• 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!

54 2063-9001-100 / 0509
Problem Cause Action
Valve does not Control unit is defective. Contact service backup

function. support.
Wire break in the connect- Replace wire.
ing terminal.
Connecting terminal on the Tighten the screw of the
connector block is loose. connecting terminal.
Bad contact on the con- Clean or replace the con-
necting terminal. tact.
Coupler socket loose. Tighten coupler socket.
Magnet coil defective. Replace the solenoid head.
Diaphragm defective. Replace diaphragm.

2063-9001-100 / 0509 55
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
Pressure transmitters PT1 and PT2

(Pressure Transmitter)
– are included in the standard scope
of supply,
– provide alarm logging PAH (Pres-
sure Alarm High) and PAL (Pres-
sure Alarm Low),
– switch process-specifically in case of
pressure drop or increase,
– can be software-checked for correct
functionality and
can be adjusted to their switching
points,
Fig. 71 – are maintenance-free.
The pressure transmitter
– PT1 is installed in the product discharge line.
– PT2 is installed on the Unitrolplus-System.
Note:
Refer to the circuit diagram 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 Unitrolplus-System
Pressure transmitter Pressure transmitter
PT1 PT2
PAL PAH PAH
(1) (2)
1.0 bar 3.0 bar 0,5 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 under the switching point.
IMPORTANT:
• Pay special attention to order-specific settings (see operating data sheet in
the order documentation)!

56 2063-9001-100 / 0509
Technical data
Voltage 24 V DC
Range 0 – 16 bar
Output signal 4 – 20 mA
Pressure connection G 1/4in outer (O-ring seal)
Tightening torque
Pressure connection max. 25 Nm
Connector plug M 12 x 1; 5-pole
Cable PUR-2 core, 1.5 m
Cable box M 12 x 1; 5-pole
Pin1-, white; Pin4+, black
Enclosure IP 67
Working temperature :
-40 to +125 °C (-40 to +257 °F)
Medium temperature
2.6.2 Water detector
The WMSwater detector (WMS sen-

sor)
– is included in the standard equip-
ment,
– is built into the unitrolplus-System,
– monitors the partial flow that is dis-
charged from the bowl via the sepa-
rating disk and the sensing liquid
pump.
– can be checked for functionality
using appropriate software.
Fig. 72
Note:
Refer to the terminal connection plan in the control cabinet and the manual of
the control system.
Setting the switching points

The switching points are preset for the specific area of application (HFL or LO)
at the factory.

2063-9001-100 / 0509 57
Technical data
Switching hysteresis Depending on the process HFO/LO
Ambient temperature -30 to +125 °C (-22 to +257 °F)
(LED: -30 to 100 °C / -22 to 212 °F )
Temperature drift dependent on medium
Enclosure (according to IEC 60529) Terminal strip: IP 54
Probe: IP 68 – 10 bar
Housing material MS
Immersion tube: PTFE
Connector plug Terminals
See terminal allocation
Connection M 30 x 1.5
Jaw span 32
Supply voltage UB 10 to 35 V DC
EMC (electromagnetic compatibility)
Conformity
according to IEC 60947-5-2)

58 2063-9001-100 / 0509
2.6.3 Solenoid valve
The solenoid valve is a 2/2-way diaph-

ragm straight-way valve with internal
piloting.
Main components:
1 Diaphragm
2 Emergency locking manual override
A Operating mode
B Emergency manual override
Fig. 73
Note: The emergency manual override (2)

– is secured against accidental activation: see operating status (A).
– can be pressed and turned through 90°: see emergency manual override (B).
Technical data
Part-No. see parts list
Operating principles 2/2-way valve normally closed
Nominal width 3 mm
Gasket material FKM
Material CuZn
Line connection G-1/4 sleeve
Voltage 24 V
Kind of current DC (direct current)
Rating 8W
In case of electrical faults


o
separator parts (separating temperatures of 70 to 100 C(158 – 212 °F)).
IMPORTANT:
• Refer to the instruction manual and nameplate of the solenoid valve.
• Direct intervention in the solenoid valve may only be done by authorised spe-
cialists and with suitable tools!

2063-9001-100 / 0509 59
Problem Cause Action

Valve does not Control unit is defective. Contact service backup
function. support.
Wire break in the connect- Replace wire.
ing terminal.
Connecting terminal on the Tighten the screw of the
connector block is loose. connecting terminal.
Bad contact on the con- Clean or replace the con-
necting terminal. tact.
Magnet coil defective. Replace the solenoid head.
Diaphragm defective. Replace diaphragm.

60 2063-9001-100 / 0509
2.6.4 Vibration monitoring (Option)

The separator is protected against inadmissibly high vibrations by means of an
electronic vibration monitoring system.
Fig. 74 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

2063-9001-100 / 0509 61
2.6.5 Speed monitoring

Speed monitoring device
• displays bowl speed.
Speed deviations of up to 5 % are permissible.
• monitors speed drop as well as excess of speed and starting time.
Fig. 75
1 Spindle • rotates and generates speed pulses at prox-

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

to control unit 3.
ATTENTION!
Align the proximity switch as illustrated.
The distance X between the spindle and the
proximity switch must be 2.5 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.
ATTENTION!
Pay attention to the terminal allocation in the terminal diagram of the
refer to the instruction manual of the control unit.

62 2063-9001-100 / 0509
2.7 Product feed and discharge lines
By fitting pre-set valves into the prod-

uct feed A and product discharge B
lines (see Section 4.2), the separator
can be adjusted to the conditions and
requirements of the throughput capaci-
ty and line pressure.
Fig. 76
2.7.1 Throughput monitoring (Product feed line A)

The effective separator throughput capacity is listed on the order-specific oper-
ating data sheet.
The required pre-set valve inner diameters for the various throughput capacities
can be taken from the following table:
Flow indicator - scale: 0 – 10

Throughput capacity Pre-set valve inner diameter
[l/h] [mm]
3 000 – 5 000 12
5 000 – 8 000 15
8 000 – 11 000 18
11 000 – 15 000 21
15 000 – 23 000 24
23 000 – 52 000 No pre-set valve
On Using the D10 Control Unit

• When starting up, use the sticker provided to mark the indicated scale range
on the flow indicator 2 (see Fig. 76).
On Using the E40 Control Unit

The effective throughput capacity is shown on the control unit.
Variations in the throughput capacity between the actual value and setpoint can
be adjusted in the control unit.

2063-9001-100 / 0509 63
2.7.2 Determining the throughput (Product feed line A)
Fig. 77 Diagram for determining throughput
A Pre-set valve inner diameter (mm)

B Throughput capacity (x 1000 l/h)
C Scale range of the flow indicator
The diagram can be used to determine the separator throughput capacity (add-
ed feed per time unit).
Procedure:
• Read the scale value at the flow indicator (see Fig. 76):
e.g. 3
• Proceed horizontally with the scale value (e.g. 3) to the curve of the fitted pre-
set valve diameter A (e.g. Ø 18).
• Vertically read off the throughput capacity B:
e.g. 10 (= 10 000 l/h)
The accuracy of the determined throughput depends on the following properties

of the feed:
– Viscosity
– Temperature
– Density
The stipulated properties can result in variations in determining the throughput
capacity.

64 2063-9001-100 / 0509
2.7.3 Pressure monitoring (Product discharge line B)

The product discharge line pressure is shown on the pressure gauge 1 (see Fig.
76).
• Note the factory settings of the switching points (see Section 2.6.1).
The required pre-set valve inner diameters for the various throughput capacities
can be taken from the following table:
Pressure gauge - measuring range: 0 – 10 bar

Throughput capacity Pre-set valve inner diameter
[l/h] [mm]
3 000 – 5 000 10
5 000 – 7 500 12
7 500 – 12 000 15
12 000 – 17 000 18
17 000 – 24 000 21
24 000 – 32 000 24
32 000 – 52 000 No pre-set valve

2063-9001-100 / 0509 65
2.8 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) 4 dm
–1
Speed 8 200 min
– for densities of the product up to
3 o (see name-plate)
1,01 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. 3 – 6 min

Run-down time
90 min
(without braking, with drive belts)
Run-down time (with braking) approx. 7 min
Run-down time (without drive belts, i.e. in
the case of torn, jumped off or defective drive 120 min
belt)
Centripetal pump
Output (depending on medium) max. 21 500 l/h
Pressure head 2 – 3 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

66 2063-9001-100 / 0509
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 11 – 15 kW
60 Hz 15 – 18 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. 3,7 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) 860 kg

Bowl 190 kg
Motor 107 kg

2063-9001-100 / 0509 67
3 Operation
3.1 Technical information ............................................................................. 68

3.1.1 Separating with the unitrolplus system .................................................. 68
3.1.2 General information on bowl ejection .................................................... 68
3.2 Before start-up ....................................................................................... 70
3.2.1 Before the first start-up – after maintenance and repair ........................ 70
3.2.2 Before every start-up ............................................................................. 72
3.3 Starting the separator ............................................................................ 73
3.4 Monitoring of operation .......................................................................... 74
3.5 Setting the separation time .................................................................... 76
3.5.1 Mathematical calculation ....................................................................... 76
3.6 Ejecting the bowl .................................................................................... 77
3.7 Shutting down the separator .................................................................. 78
3.8 Trouble shooting .................................................................................... 82
3.8.1 Troubleshooting the separator ............................................................... 82
3.8.2 Bowl faults.............................................................................................. 84

68 2063-9001-100 / 0509
3.1 Technical information

Take note of the following sections:
3.1.1 Separating with the unitrolplus system

The separator with unitrol plus-System has two built-in monitoring functions:
– water content monitoring system - WMS
– sludge space monitoring system - SMS
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 time at which the ejection is triggered is
• determined by the preset separating time
or
• by the solids level in the bowl,
if:
– SMS was selected on the control unit,
– the sludge space is full before the separating time has elapsed.
For determining the separating time see 3.5.
Sequence of an ejection (example without “Filling”)

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. Product valve is opened.
7. Separating time resumes.
Displacement
• 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).

2063-9001-100 / 0509 69
• 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.
Flush ejection
If the solids cant be completely ejected,
– due to an excessively long dwell time in the bowl or
– are stuck too 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" 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.

70 2063-9001-100 / 0509
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
ATTENTION!
In order not to endanger the operating safety of the separator, keep
to the recommended maintenance intervals.
If the bowl has been out of operation for longer than 6 months (e.g. due
to a long standstill period or storage),
• check all bowl parts as specified in the maintenance schedule (table “Main-
tenance after 4000 operating hours or after 6 months at the latest”).
• Replace if necessary.
If the separator has been out of operation for longer than 12 months (e.g.
due to a long standstill period or storage),
• check all separator parts in accordance with the maintenance schedule (ta-
ble “Maintenance after 8000 operating hours or after 1 year at the latest).
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 bowl height is correct (see section 4.7.1).
• the brake housing is correctly mounted.
• the brake is released by turning the handle clockwise.
• the bowl can be rotated by hand.
• the machine is correctly assembled.
– Tighten the bowl lock ring securely (left-hand thread).
– Tighten the spindle screw with the separator-specific torque (left-hand
thread).
– Tighten the centripetal pump lock ring securely (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).

2063-9001-100 / 0509 71
• 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 supervisory equipment is complete, mechanically and electrically func-
tional.
• the product and supply lines are ready-for-operation.
– Pay attention to the air and water pressures (see order-specific operating
data sheet).
• the product heating devices are ready for operation (option).
– Pay attention to the volumes, pressure and temperature (see order-specific
operating data sheet).
• the plant components such as valves, water pressure reducer, compressed
air control unit etc. are operational.
• the motor is correctly connected 4.1.3.
• the motor is correctly mounted.
Im p o rta n t!
• Check the remaining 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.

72 2063-9001-100 / 0509
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 brake housing is correctly mounted.
• the brake is released by turning the handle clockwise.
• the machine is correctly assembled.
– Tighten the bowl lock ring securely (left-hand thread).
– Tighten the spindle screw with the separator-specific torque (left-hand
thread).
– Tighten the centripetal pump lock ring securely (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 undamaged and connected (see section 4.3.2).
• the feed and discharge lines are connected (see 4.5).
• the supervisory equipment is complete, mechanically and electrically func-
tional.
• the product and supply lines are ready-for-operation.
– Pay attention to the air and water pressures (see order-specific operating
data sheet).
• the product heating devices are ready for operation (option).
– Pay attention to the volumes, pressure and temperature (see order-specific
operating data sheet).
• the plant components such as valves, water pressure reducer, compressed
air control unit etc. are operational.
• the motor is correctly mounted.
Im p o rta n t!
• Check the remaining plant components such as hose pipes, sight glasses for
signs of aging and mechanical damage.

2063-9001-100 / 0509 73
3.3 Starting the separator

• See section 3.2.1 or 3.2.2
• Switch on the control unit.
• Switch on the separator motor.
Compare the starting current and starting time with the diagram (section
4.1.3) until the bowl reaches the speed specified on the separator nameplate.
Note:
The run-up phase of the separator motor is signalled by slow flashing of the
LED in the “Status Separator” key.
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 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. 78
• Switch on the product feed pump (option).

– Ensure that the product feed valves to the suction and pressure side 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).
P re -c o n d itio n s :
– 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).

74 2063-9001-100 / 0509
• Open the shut-off flap in the solids

discharge (option).
1 Shut-off flap
2 Solids tank
3 Solids discharge
Fig. 79
• Start the program.

P re -c o n d itio n s :
– 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 approx. 1.5 to 2.5 bar
(see order-specific operating data sheet).
– Adjust the desired throughput capacity; while doing so, maintain the back-
pressure in the product discharge line in the specified area.
ATTENTION!
• Check the discharges for solids and dirty water; there must be no oil flow
during the separating process!
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)!

2063-9001-100 / 0509 75
• 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.

76 2063-9001-100 / 0509
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: Solids content p = 0.05 %
Solids holding space volume V = 1,5 l
Solids holding space given 75 % utilisation V' = 1,13 l
(1) o
Throughput capacity V = 2 000 l/h
Wanted: Separating time t = ? min
The separating time to be set is calculated as follows:
V’ 1,13
t = ——— • 60 • 100 = —————— • 6 000 = 67,8 min = 1,1 h
V° • p 2 000 • 0.05
(1)
Solids content and throughput capacity must be determined on site or taken from
the order specification.

2063-9001-100 / 0509 77
3.6 Ejecting the bowl
Automatic operation
• Initiate ejection program by pressing the key ”Process START”:

– Product feed is closed.
– Displacement
– 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.
• 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.
• New separating operation
– Open the product feed valve manually.

78 2063-9001-100 / 0509
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 90 minutes after switching off the motor
(without braking!).
– Bowl standstill is indicated by standstill of the drive belt.

2063-9001-100 / 0509 79
Standstill of drive belt

• Shine a torch through the frame
sight glass.
• Visually check that the drive belt is
no longer moving.
Fig. 80
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.

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 120 minutes until dismantling the
separator!
• Applying the brake is not effective!
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. 81

80 2063-9001-100 / 0509
Risk of injury due to electrical vol-

tage and unintended start-up of the
separator!

ponents:
Fig. 82

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),
ditional connection for an external “Emergency-Off”-switch (example 2) or
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.

Fig. 83 Example 1

2063-9001-100 / 0509 81
“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.

Fig. 84 Example 2

82 2063-9001-100 / 0509
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 Troubleshooting the separator
Failure Possible causes Action

The bowl does not come up Brake is applied. • Release brake by turning the handle
to rated speed or takes too clockwise.
long to do so. Oil has run down the spindle onto the • Clean belt contact surface of the
drive belt; the drive belt is slipping on spindle and flat belt pulley.
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 • Checking operating water dis-
section of frame and is braking the charge: 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. • IMPORTANT: Do not use
benzene, trichlorethy-
lene or any other sol-
vent!
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 quickly (in less • Make sure that the
than 1,5 minutes). Starting clutch shoes are
current of motor is thus inad- evenly spaced.
missibly high (Imax >2 x IN).

2063-9001-100 / 0509 83

Uneven run of the centrifuge. Bowl is out of balance for the following For pos. 1 - 4:
reasons: • Shut down separator.
• Apply brake.
• 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 lock ring is not screwed CAUTION: A loose lock
to the "O" mark. ring can endanger life!
• The 0 marks on
the bowl bottom
and lock ring must
be aligned.
– Insufficient number of disks in- • Check number of disks, if applicable

stalled. add a disk.
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.

84 2063-9001-100 / 0509
3.8.2 Bowl faults
Fig. 85 Bowl and operating water feeding system
1 Gasket (bowl top) 13 Operating water feeding system

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

2063-9001-100 / 0509 85
The bowl does not close. Operating water

Control unit is defective or • Check control unit.
IMPORTANT: Motor is not correctly set. • Check program parameters and
– Product flows out of the
reset if possible.
solids discharge.
(See control unit instruction ma-
– Current consumption is too
nual.)
high.
Closing water pulse too short. • Set 3 seconds (see also control unit
manual).
Strainer 66.04 cm the operating, filling • Close shut-off cock 27.
and displacement water line is dirty. • Clean strainer 26 (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 sec
The operating water line 28 has be- • Clean or replace operating water
come constricted due to dirt accumula- line 28.
tion or damage. Insufficient operating
water is entering the injection
chamber.
The operating water solenoid valve 23 • Check and replace solenoid valve
does not open properly. 23.
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.
Gaskets, guide bands, piston guide • Replace all seals.
ring are damaged or Use set of spare parts "bowl/hood“
(see spare parts list).
Important: Time-consuming instal-
lation!
• Only replace the polyamide gasket 5
if damaged (see section 4.4.9)!
Sealing surface of sliding piston 20 is • Very slightly remachine the sealing
damaged. surface – max. 1 mm! – (see sec-
tion 4.4.10) or
• send in the sliding piston for repair.

86 2063-9001-100 / 0509

ter
26 Strainer
27 Shut-off valve

2063-9001-100 / 0509 87
The bowl does not open, or Operating water

only partially so Control unit is defective or • Check control unit.
Motor is not correctly set. • Check program parameters and
reset if possible.
(See control unit instruction ma-
nual.)
Time for opening water too short. • Set 3 – 4 seconds (see also control
unit manual).
Strainer 66.04 cm the operating, filling • Close shut-off cock 27.
and displacement water line is dirty. • Clean strainer 26 (see 4.4.4 ).
The operating water capacity is too • Check line pressure, increase if
low. necessary.

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
chamber.
The operating water solenoid valve 23 • Check and replace solenoid valve
does not open properly. 23.
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.
– Carefully check and clean drain
hole 19.
Gaskets, guide bands, piston guide • Replace all seals.
ring are damaged. Use set of spare parts "bowl/hood“
(see spare parts list).
Important: Time-consuming instal-
lation!
• Only replace polyamide gasket 5 if
damaged (see section 4.4.9)!
• Carefully check polyamide gasket 5
for firm seating in the groove.

88 2063-9001-100 / 0509

ter
26 Strainer
27 Shut-off valve

2063-9001-100 / 0509 89

The bowl does not empty The operating water capacity is too • Check line pressure, increase if
completely. Solids remain in low. necessary.
the bowl.
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. • Correct closing water impulse (see
ration. – Closing water has evaporated. control unit documentation).
Closing water pulse is too long.
– Closing water impulse opens the
bowl.

90 2063-9001-100 / 0509
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note

2063-9001-100 / 0509 91
4 Installation - Maintenance - Repair
4.1 Installation of the separator ................................................................... 92

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 Valves and flow indicator ..................................................................... 103
4.2.1 Installing valves ................................................................................... 104
4.3 Maintenance and lubrication ................................................................ 105
4.3.1 Maintenance schedule ......................................................................... 105
4.3.2 Hoses and hose pipes ......................................................................... 112
4.3.3 Lubrication ........................................................................................... 113
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 Westfalia
Separator ............................................................................................. 119
4.4 Bowl ..................................................................................................... 120
4.4.1 Dismantling the bowl ............................................................................ 122
4.4.2 Cleaning the bowl ................................................................................ 142
4.4.3 Cleaning the frame .............................................................................. 143
4.4.4 Cleaning the strainer and the operating water feeding system ........... 143
4.4.5 Cleaning the motor .............................................................................. 144
4.4.6 Important instructions for assembling the bowl ................................... 145
4.4.7 Assembling bowl .................................................................................. 147
4.4.10 Reworking the sliding piston ................................................................ 171
4.5 Closing the hood .................................................................................. 172
4.6 Drive ..................................................................................................... 174
4.6.1 Important instructions for fitting and removing the drive ...................... 176
4.6.2 Removing the drive belt and spindle assembly ................................... 178
4.6.3 Dismantling the spindle assembly ....................................................... 183
4.6.4 Dismantling the centrifugal clutch ........................................................ 185
4.6.5 Fitting the spindle assembly ................................................................ 189
4.6.6 Fitting the centrifugal clutch ................................................................. 192
4.6.7 Replacing the neck bearing springs (neck bearing bridge) ................. 199
4.6.8 Fitting the motor ................................................................................... 202
4.7 Height adjustment ................................................................................ 207
4.7.1 Bowl height .......................................................................................... 207
4.7.2 Centripetal pump clearance ................................................................. 209
4.8 Final checks after assembling the separator ....................................... 211
4.9 Before a long-term shut-down of the separator ................................... 211
4.9.1 Preserving the separator ..................................................................... 211
4.9.2 Preserving the motor ........................................................................... 212
4.10 Storage ................................................................................................ 213
4.10.1 After delivery ........................................................................................ 213
4.10.2 Separator ............................................................................................. 213
4.10.3 Control system ..................................................................................... 213
4.11 Before restarting .................................................................................. 214
4.12 Disposal ............................................................................................... 215
4.12.1 Gear and lubricating oils ...................................................................... 215
4.12.2 Cleaning liquids ................................................................................... 216
4.12.3 Separator ............................................................................................. 216
4.13 Standard tools ...................................................................................... 218
4.14 Special tools ........................................................................................ 220

92 2063-9001-100 / 0509
4.1 Installation of the separator
• For further information see installation guidelines.

Water detector:
Center of gravaty
The complete bowl can then be Solids discharge

transported via the adjacent Water / operating water discharge
separators of the same type.
Filling, displacement and operating water supply
Product discharge
Water / operating water discharge
Product discharge
Solids discharge


2063-9001-100 / 0509 93
Min. lifting capacity of hoist: 500 kg

For maintenance and repair
Bowl, motor
Center of gravity
Connectors:
Product feed
Product discharge
Discharge via the centripetal pump installed in the separator Water discharge
Operating water discharge
Solids discharge
Filling, displacement and operating
water supply
Solenoid valve block

Filling, displacement and Klemmenkasten
operating water

Water detector:
Service side
The foundation must not contact the foundations of other units (e.g. auxiliary diesel en-
gines, pumps) in order to prevent damage to ball bearings.


94 2063-9001-100 / 0509
4.1.1 Transporting the separator
• CAUTION: Use appropriate lifting devices to prevent accidents!

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

– Do NOT step under hanging load.
• Always transport the separator without installed bowl!
• For special tools, see section 4.14 or parts list.
• Unscrew the screw plug 1 from the

lower part of the frame.
Fig. 90
• Make sure that two eye bolts 1

have been screwed into the upper
section of frame.
• Screw double nipple 2 into the hole
in the frame.
Fig. 91

2063-9001-100 / 0509 95
• CAUTION! Do not use the eye bolt

of the motor to suspend the sepa-
rator.
• IMPORTANT: Do not damage any

machine attachment parts when fas-
tening the ropes.
• Attach the transport ropes

– around the double nipple,
– Thread through the eye bolts and
IMPORTANT: Prevent the ropes from

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

down gently.
Fig. 92
• Unscrew two eye bolts 1 and double

nipple 2.
Fig. 93
• Screw in the screw plug 1.
Fig. 94

96 2063-9001-100 / 0509
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 section
4.1.1).
• Weld plates 3 to foundation 4.
• Place the separator on plates 3 and
• bolt tight with hexagon nuts 5.
• Screw tight hex head screws 6.
Fig. 95

2063-9001-100 / 0509 97
4.1.3 Motor
Fig. 96 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. 3 – 11 – 15 – IM ISO-

3 3 000 3 600
plate 6 15 18 V1 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 2063-9001-100 / 0509
– 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.
Germany in accordance with the rules and regulations of the VDE (Associa-
tion of German Electrical Engineers) or of the local electric power company.
• Any work on the motor may be carried out by an authorized electrician
only.
• Connect the motor.

Refer to the motor instruction man-
ual.
Fig. 97 Connection scematic
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.

2063-9001-100 / 0509 99
Star switching (example)
Fig. 98
Delta switching (example)
Fig. 99
IMPORTANT:
• 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 2063-9001-100 / 0509
4.1.4 Direction of rotation of the bowl
• Fill the drive chamber with oil up to

the half way mark on the sight glass.
• Switch on the motor.
Fig. 100
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. 101

operation:
• Before working on the motor,
note that residual voltage may be
present!
• In this connection:
– Read the documentation supplied
by the frequency converter manu-
facturer.
– Have protective measures imple-
mented by suitably qualified per-
sonnel.
Fig. 102

2063-9001-100 / 0509 101
4.1.5 Speed and starting time of the bowl
Speed see name-plate

– for densities of the product up to
3
max. 1,01 kg/dm and
– for densities of separated solids up to
3
max. 1,4 kg/dm
Starting time approx. 3 – 6min
The bowl speed has been rated so as to ensure the operating safety of the se-
parator.
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. 103

102 2063-9001-100 / 0509
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. 104 – motor frequency (see nameplate
and frequency converter display!)
coincide with the separator speed.

2063-9001-100 / 0509 103
4.2 Valves and flow indicator

A set of valves (with various inner diameters) and a set of commissioning parts
are included in the separator delivery.
– The set of valves is attached to the separator hood.
– The commissioning parts set includes flow indicator 3.
Mounting of a valve allows separator flow rate monitoring.
Fig. 105
A Product feed line

B Product discharge line
1 Pre-set valve
2 Pre-set valve
3 Flow indicator
4 3/2-way valve
ATTENTION! Pay attention to mounting of the following parts before

commissioning the separator:
Valves 1 and 2
• Select valves according to required flow capacity from the provided valve set
(see section 2.7).
• Mount valve 1 on product feed line A (see section 4.2.1).
• Mount valve 2 on product discharge line B (see section 4.2.1).
Flow indicator 3
• Remove plug from the corresponding bore of 3/2-way valve 4.
• Secure threading of flow indicator 3 with Loctite 245.
• Install flow indicator 3 on 3/2-way valve 4.

104 2063-9001-100 / 0509
4.2.1 Installing valves

Valve installation is explained by example for product discharge line B.
Required equipment:
– Open-ended wrench
– Lubricating grease
• Screw off corrugated hose 3.

• Insert selected valve 2 in connector
1 and push in evenly by hand.
Fig. 106
• Lightly lubricate threading of con-

nector 1.
• Insert corrugated hose 3 and firmly
tighten with hexagon nut 2.
Fig. 107

2063-9001-100 / 0509 105
4.3 Maintenance and lubrication
• Special care must be taken when performing maintenance and lubrication

operations.
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 be carried out only by persons
– who are demonstrably familiar with the state-of-the-art through briefings
and training.
– who are adequately qualified for performing the work and checking it.
• Electrical work may only be carried out by an authorized electrician!
• Use only genuine spare parts from Westfalia Separator.
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 – Hoses and hose pipes (see 4.3.2)
– Leakage – Pipe joints
– Vibrations
• Before every assembly, grease the main components of the bowl at guide and contact surfaces (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 time. We recommend checking the clutch shoes after 1000 operating hours or after 2 months at the latest.
• We recommend having the separator checked by a WS service specialist once a year.

106 2063-9001-100 / 0509
Fig. 108 Set of spare parts „bowl/hood“ (operation: 1 year or 8,000 hours)

2063-9001-100 / 0509 107
Commissioning date:
(to be filled in by user)
Maintenance work Remark

– After 4000 operating hours – after 6 months at the latest
– After 12,000 operating hours – after 1 ½ years at the latest
Bowl inspection • Dismantle 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 (see accompanying illustration). • Use set of spare parts "bowl/hood“
(Operation: 1 year or 8,000 hours).
See spare parts list.
Important: Time-consuming installation!
Only replace polyamide gasket 100 if damaged (see section
4.4.9)!
Check the motor. • See instructions of motor manufacturer
Re-lubricate motor bearings (if required)
When using mineral oil: • See section 4.3.3 - oil quality and oil change.
Oil change and thorough cleaning of 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-return valve.
Carefully clean the water detector (if installed) with a soft
cloth, use diesel oil if necessary.
Clean the sight glass/glasses in the frame for observation
of 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 2063-9001-100 / 0509

2063-9001-100 / 0509 109

– After 8000 operating hours – after 1 year at the latest
– After 24,000 operating hours – after 3 years at the latest
system.
when fitting.
Replace gaskets, piston guide ring and guide bands (see • Use set of spare parts "bowl/hood“
accompanying illustration). (Operation: 1 year or 8000 hours).
See parts list.
4.4.9)!
Clean the inside of the upper section of frame. • Remove bowl.
Check or replace neck bearing springs. • See section 4.6.7.
Replace gaskets. • Use set of spare parts "drive"
Replace the drive belt. (Operation: 1 year or 8000 hours).
Replace cylindrical roller bearings and angular contact ball See spare parts list.
bearings of spindle.
Check ball bearings of centrifugal clutch and replace if • Use set of spare parts "drive"
necessary. (Operation: 2 years or 16000 hours).
Check thickness of clutch shoes(1), replace if See spare parts list.
h is smaller than 18 mm.
New condition of clutch shoe h = 26 mm
Check thickness of brake lining and replace when New condition of the fitted brake lining
h = 10 mm

Oil change and thorough cleaning of 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 only after motor or drive replacement.
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.
of the drive belt.
sary.
Check that vibration absorbers are fully functional (option).
(option).
(1) In the case of frequent starting and stopping of the separator, shaft-driven alternator operation and in power plants, shorter mainten-
ance intervals are required. It is not possible to state a definitive time. 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 2063-9001-100 / 0509

2063-9001-100 / 0509 111

system.
when fitting.
Replace gaskets, piston guide ring and guide bands (see • Use set of spare parts "bowl/hood“
accompanying illustration). (Operation: 1 year or 8000 hours).
See parts list.
4.4.9)!
Clean the inside of the upper section of frame. • Remove bowl.
Check or replace neck bearing springs. • See section 4.6.7.
Replace gaskets. • Use set of spare parts "drive"
Replace the drive belt. (Operation: 2 years or 16000 hours).
Replace cylindrical roller bearings and angular contact ball See spare parts list.
bearings of spindle.
Replace ball bearings of centrifugal clutch.
Check thickness of clutch shoes(1), replace if
New condition of clutch shoe h = 26 mm
Check thickness of brake lining and replace if New condition of the fitted brake lining:
h = 10 mm

Oil change and thorough cleaning of 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 only after motor or drive replacement.
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.
of the drive belt.
sary.
Check that vibration absorbers are fully functional (option).
(option).
(1) In the case of frequent starting and stopping of the separator, shaft-driven alternator operation and in power plants, shorter mainten-
ance intervals are required. It is not possible to state a definitive time. 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 2063-9001-100 / 0509
Maintenance work
Equip the separator with new vibration isolators.

We recommend having the separator checked by a WS service engineer.
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.
Protective hose 1
• Fit the protective hoses at all contact

points to the separator.
• Adapt the length of the protective

hose.
Fig. 111

2063-9001-100 / 0509 113
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 Westfalia Separator with the designation "Separa-
tor 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 Westfalia Separator AG!
Designation according to ISO Mobil SHC 626

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.

114 2063-9001-100 / 0509
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. 3,7 litres
Fig. 112
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. 113
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.

2063-9001-100 / 0509 115
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note

116 2063-9001-100 / 0509
4.3.4 Lubrication Chart
Fig. 114 Lubrication schedule

2063-9001-100 / 0509 117
Lubricant Lubrication frequency

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

4 000 2x 3 700 cm Drive chamber
(mineral)
1
CC 100
ISO 3498
Lube oil Mobil SHC 626 3

8 000 1x 3 700 cm Drive chamber
(synthetic) ISO VG 68
2 according to instructions of motor manufacturer Motor bearings
Threads and sliding sur-

3 2x
faces of bowl
Lubricating see
4 as required 1x apply sparingly Threads of fittings
grease parts list
Manually-operated parts
5 1x
such as locking brake
• Check oil level regularly through sight glass.

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

118 2063-9001-100 / 0509
4.3.5 Table of lubricating oils
Lubricating oil sorts suggested by some firms
Manufac-
Viscosity
Designation at 40 °C (104 °F)
turer
mm2/s (cSt)
Lubricating oil table
for separators in onshore and shipboard opera- BLASIA 100
tion RADULA 100 100
DIESEL GAMMA 30
Separator Lube oil
ATLANTA MARINE 30
Viscosity 105
(Designation accord-
DISOLA M 3015
ing to DIN 51502)
MONTANOL HK 100 100

Oil filling
Kinematic
Symbol
Type viscosity ENERGOL GR-XP 100 100

at 40 °C ENERGOL DL-MP 30 114
(104 °F)
2
l mm /s (cSt) HYSPIN AWS 100
100
BTC 3 ALPHA ZN 100
CTC 1 MARINE HEAVY 99
CTC 3
MTC 3 1.3 GST OIL 100
100
OTC 2 NL Gear Compound 100
OTC 3 Veritas Marine Oil R&O 30 108
WTC 2 DELO 3000 Marine Oil 30 104
ATLANTA MARINE 30
105
CSD 1 DISOLA M 3015
OSD 2 1.3 TURBINE T 100 95
SD 1
EXX-MAR XP 110
NUTO H 100
100
SPARTAN EP 100
ESD 18 GULF HARMONY 100 95

GSC 15 VERITAS 30 110
OSD 6 CLP 90 to 110 0015-0003-080
OSD 18 2.5 HIDRAOIL HD 70 95
100 (2.5 l)
WSD 8
WSD 18
OSE 10 MOBILGARD 312 106
OSE 20
GADINIA 30 104
GSC 25 ROTELLA MX SAE 30 105
OSD 20
OSD 25
OSD 30 3.7 HYDRA WAY HMA 100
100
OSD 35 LOAD WAY EP 100
SD 30
WSD 35
OSE 40 DORO AR SAE 30 119
OSD 50 TARO XD SAE 30 105
OSD 60
OSD 80
5.0
SD 50
WSD 60
OSE 80

2063-9001-100 / 0509 119
4.3.6 Comments on table of lubricating oils for separators from Westfalia Separator
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 to use the oils specified by us since continuous qual-
ity checks are performed by Westfalia Separator. Oils proposed from some firms are not subjected to
these tests.
Therefore, Westfalia Separator 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 Westfalia Separator.
For the different separator types and oil types the viscosity ranges are specified in the table of lubricating
oils.
The operating temperature of the separator exceeds normally 80 oC (176 oF). 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.
Bear in mind that the viscosity groups SAE 30, 40 and 50 (SAE = Society of Automotive Engineers)
cover larger viscosity ranges and be sure to select lubricating oils with viscosities not lower than the
minimum values of the viscosity ranges restricted for the different separator types.

120 2063-9001-100 / 0509
4.4 Bowl
Fig. 115 Exploded view of the bowl and centripetal pump

2063-9001-100 / 0509 121
Pos. Designation Dimensions
20 (1) Bowl bottom, compl.

30 Gasket
40 Piston guide ring
50 (2) Water chamber bottom
70 Gasket
80 Allen screw ISO 4762 - M 10 x 16 -1.4571
90 Annular piston
100 Gasket
110 Gasket
120 Closing chamber bottom
130 Gasket
140 Gasket
160 Guide strip
170 Allen screw ISO 4762 - M 12 x 25 - A4-80
180 Sliding piston
190 Gasket
200 Guide strip
210 (1) Distributor
220 Disk stack, complete
230 Separating disk
240 (1) Bowl top, complete
250 Gasket
260 Gasket
270 Gasket
280 (2) Lock ring
290 Threaded pin ISO 4026 - M 12 x 16 -1.4571
300 Gasket
310 Gasket
320 Centripetal pump chamber
cover, compl.
330 Centripetal pump chamber
cover
340 Lock ring
350 Spindle screw:
360 Gasket
510 Centripetal pump, compl.
520 Gasket
530 Sensing liquid pump
540 Gasket
550 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 2063-9001-100 / 0509
4.4.1 Dismantling the bowl


still.
(without braking!).

sight glass..
no longer moving.
Fig. 116


still.
separator!

o

2063-9001-100 / 0509 123


Germany in accordance with the rules and regulations of the VDE (Verband
Deutscher Elektrotechnik/ Association of German Electrical Engineering) or of
only.
• Avoid damage to bowl parts when fitting and removing by

– precise positioning,
– no diagonal pull!
– selecting the low lifting speed of the hoist.
CAUTION: Use appropriate lifting devices to prevent accidents!

• Use suitably rated, intact hoists.

CAUTION: Avoid accidents by using undamaged, complete tools!

• Use tools only for their intended use!
– For special tools, see section 4.14 or spare parts catalog.
– For standard tools, see section 4.13.
• Do not use force when removing or fitting parts.
• Treat all bowl parts

– gently.
– 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 serial number of the machine or the last
three digits of the serial number.

124 2063-9001-100 / 0509
CAUTION:
• Certain bowl parts (see sect. 4.4)
may be pre-assembled and bal-
anced only by specialists from
Westfalia Separator or in work-
shops authorized by Westfalia
Separator.
Unqualified balancing can lead to
dangerous operating states (vi-
brations) and destruction of the
separator with danger to life.
Fig. 117
Hinge up hood
• Unscrew filling and displacement

water line 1.
Fig. 118
• Unscrew the handle connection

piece by lightly hammering with a
mallet (left-hand thread), at the
same time
• hold the centripetal pump with sock-
et wrench 2.
Fig. 119

2063-9001-100 / 0509 125
• Remove handle connection piece 1.
Fig. 120
• Unscrew four hex head screws with

washers.
Fig. 121
• Hinge up hood.
CAUTION: Danger of injury by in-

correct hinging up of the hood!
• The stirrup must register properly.
Fig. 122
If necessary (see section 4.3.1:

• Take gasket 1 out of the upper sec-
tion of the frame.
Fig. 123

126 2063-9001-100 / 0509
Remove centripetal pump
Required special tools

– Ring spanner
– Mallet
• Undo the centripetal pump chamber

lock ring by striking the arm of the
ring spanner using a mallet (left-
hand thread).
Fig. 124
• Unscrew the centripetal pump

chamber lock ring 1 by hand and
remove it.
• Press off centripetal pump chamber
cover 2 using a screwdriver.
Fig. 125
• Screw handle connection piece into

the centripetal pump (left-hand
thread).
• Lift off the complete centripetal
pump and centripetal pump chamber
cover together.
Fig. 126

2063-9001-100 / 0509 127
• Screw centripetal pump chamber

lock ring on bowl top (left-hand
thread).
Fig. 127
• Position the complete centripetal

pump with chamber cover onto cen-
tripetal pump chamber lock ring.
• Screw handle connection piece one
turn into the centripetal pump (left-
hand thread).
• Detach the sensing liquid pump by
striking lightly with a mallet.
Fig. 128
• Remove the following parts:

– sensing liquid pump 1 with in-
serted gaskets,
– centripetal pump chamber cover 3
with gaskets 2 and
– centripetal pump 4 with inserted
gasket.
Fig. 129

chamber lock ring (left-hand
thread).
Fig. 130

128 2063-9001-100 / 0509
Lifting out the bowl
Required special tool

– Socket wrench
• Unscrew the spindle screw (with

inserted gasket) with socket wrench
and commercially available ratchet
wrench (left-hand thread) and re-
move it.
Fig. 131

– Eye bolt 1
• Unscrew hexagon nut 2

• Screw eye bolt 1 into the bowl bot-
tom.
• Force the bowl off the spindle cone
using an open ended wrench
Fig. 132
• CAUTION: Danger to life when

transporting heavy parts!
• Lift the bowl out of the frame with
the aid of a hoist.
• Set the bowl down on a rubber mat
or a wooden pallet for further dis-
mantling.
Fig. 133

2063-9001-100 / 0509 129
Compressing the disk stack
• Clean the threads in the distributor 1

with a brush.
• Grease the thread of bowl top 2 (see
chapter 4.3.4).
Fig. 134

Compressing device
– Bolt unit 1
– Bell-shaped piece 2
Fig. 135
Bolt unit 1 comprises ring nut, lever, and bolt.

– The ring nut must always be screwed into the bolt and be secured with Loctite
275.
– The lever must always have smooth impingement surfaces (deburr if neces-
sary).
• Grease the thread and contact sur-

face of bell-shaped piece 2 (see
chapter 4.3.4).
• Place bell-shaped piece 2 on the
bowl top.
– The O marks of the bell-shaped
piece and the bowl bottom must
be aligned.
• Screw on centripetal pump chamber
lock ring 3 as far as it will go (left-
hand thread).
Fig. 136

130 2063-9001-100 / 0509
• Screw bolt unit 1 through the bell-

shaped piece and thread it into the
distributor as far as it will go, using
an open-ended wrench.
Fig. 137
• Unscrew two threaded pins from the

bowl lock ring.
Fig. 138

– complete ring spanner 1
• Remove two hexagon nuts 3 from

hex head screws 2.
Fig. 139
Important:
• The O-marks of the bowl lock ring
and of the bowl bottom must be visi-
ble.
– Do NOT hide them under ring
spanner 1!
• The arrow and the "open" mark must
show upwards.
• Bolt ring spanner 1 to the bowl lock

ring.
• Screw in two hex head screws 2 of
Fig. 140 the ring spanner and tighten firmly.

2063-9001-100 / 0509 131
• Screw on the lever until it rests on

the bell-shaped piece.
• CAUTION: Danger of injury
through rotating lever!
– Be careful when working in the
area around the lever.
• Firmly hit the lever with the mallet.
– The disk stack is thus com-
pressed.
Fig. 141

through the lever!
• Strike open the bowl lock ring with a
mallet (left-hand thread).
– The bowl lock ring is thus un-
screwed from the thread of the
bowl bottom.
Fig. 142

• Hold the bowl lock ring together with

the ring spanner and lift them off us-
ing chains and hoist.
Fig. 143

132 2063-9001-100 / 0509
Remove bowl top
• CAUTION: Risk of injury through

rotating lever!
– Work cautiously in the area
around the lever.
• Carefully loosen bolt unit with mal-
let.
Fig. 144
• Remove bolt unit from distributor

using the wrench.
Fig. 145
• Screw bolt unit into the bell-shaped

piece.
• Screw the bolt unit far enough to
display thread start (see detail).
Fig. 146

2063-9001-100 / 0509 133
• Before lifting off the bowl top, check

that the centripetal pump chamber
lock ring is firmly bolted to the bowl
top.
CAUTION: Danger to life when

• Carefully lift off only the bowl top
(with fitted gaskets) using the centri-
petal pump chamber lock ring, bolt
unit and hoist.
Fig. 147
– Immediately interrupt transport if
the bowl bottom is lifted more than
1 cm above the positioning sur-
face.
– With a few mallet strikes to the edge of the bowl bottom, carefully separate
the bowl top from it.
– If the bowl top cannot be separated from the bowl bottom because of heavy
soiling, lower again and remove as follows.

134 2063-9001-100 / 0509
Remove heavily soiled bowl top (see Fig. 148 to Fig. 154):
Additional required special tools

– Disk 3
Fig. 148
• Screw bolt unit 1 into the distributor

with a wrench as far as it will go.
Fig. 149
• Turn lever 1 to under the eye bolt.

chamber lock ring 2.
Fig. 150

2063-9001-100 / 0509 135
• Raise bell-shaped piece 1.

• Slide washer 2 on the bolt offset
(see detail).
Fig. 151
• Set bell-shaped piece 2 back on

bowl top.
– The 0 mark on the bell-shaped
piece and bowl top must be
aligned.
• Screw in centripetal pump chamber
hand thread).
Fig. 152
• Completely unscrew the bolt unit

from the distributor by turning coun-
ter-clockwise with wrench complete-
ly to end of thread.
– The bowl top is forced off.
Fig. 153

136 2063-9001-100 / 0509
• Before lifting off the bowl top, check

that the centripetal pump chamber
lock ring is firm ly bolted to the bowl
top.
CAUTION: Danger to life when

• Only lift off the bowl top.
– Immediately interrupt transport if
the distributor is lifted together
with the disk stack.
Fig. 154
• Carefully lift off the bowl top (with fitted gaskets) using the centripetal pump
chamber lock ring, bolt unit and hoist.
• Detach the compressing device from the bowl top.
Remove separating disk
• Remove separating disk from dis-

tributor neck.
Fig. 155
Remove disk stack and distributor
• Screw the bolt unit of the compress-

ing device into the distributor with
the wrench.
Fig. 156

2063-9001-100 / 0509 137

• Using bolt unit and hoist, lift off and
set aside distributor together with
disk stack.
• Remove hoist and screw out bolt
unit.
Fig. 157
Remove sliding piston
• Insert spindle screw 1 in the hub.
Fig. 158
• Lubricate sliding piston 1 thread

(see section 4.3.4).
• Screw bell-shaped piece of com-
pressing device on sliding piston.
shaped piece into the sliding piston.
Fig. 159

138 2063-9001-100 / 0509
• Force the sliding piston from the

bowl bottom by turning clockwise.
Fig. 160

• Remove the sliding piston (with fitted
gaskets) using bolt unit, bell-shaped
piece and hoist.
unit.
Fig. 161
Remove annular piston and closing chamber bottom
• Loosen the twelve Allen screws

holding the closing-chamber bottom
and the bowl bottom together.
Fig. 162

2063-9001-100 / 0509 139

– Compressing device:
Bolt unit 1
Bell-shaped piece 2
– Assembling device 3
Fig. 163
• Mount bell-shaped piece 1 in bowl

bottom.
• Mount assembling device 2 on bell-
shaped piece 1.
• Loosen three Allen screws 3 with
ratchet (using extension and insert).
• Slide washers 4 of the assembling
device outward under the edge of
the annular piston 5.
• Make sure that washers 4 properly
bite under the annular piston.
• Firmly re-tighten three Allen screws
Fig. 164 3.
• Screw bolt unit 1 into the bell-

shaped piece.
• Force off closing chamber bottom 3
together with annular piston 4 by
turning bolt unit clockwise.
Fig. 165

• Lift out closing chamber bottom 3
and annular piston 4 (with fitted
gaskets) using hoist.
Fig. 166

140 2063-9001-100 / 0509
• Drive apart annular piston 1 and

closing chamber bottom 2 with mal-
let as illustrated.
Fig. 167
• Remove spindle screw 1.
Fig. 168
If necessary:
• Remove gasket 1 and piston guide
ring 2.
Fig. 169

2063-9001-100 / 0509 141
Remove water chamber bottom

– Eye bolt 1
• Unscrew hexagon nut 2.

• Screw eye bolt 1 in bowl bottom and
firmly tighten with wrench.
Fig. 170

• Attach bowl bottom in the load hook
of the hoist and lift to eye level.
• Remove four Allen screws 1 from

water chamber bottom 2.
• Force off water chamber bottom 2
with a screwdriver and remove with
fitted gaskets.
Fig. 171

142 2063-9001-100 / 0509
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 section
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. 172
• 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. 173
• 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!

2063-9001-100 / 0509 143
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 themaintenance schedule (section 4.3.1),
– dismantle the bowl (section 4.4.1).
IMPORTANT: Cleaning liquid is es-

caping!
When the bowl has been removed, no
cleaning liquid must spill onto the drive
belt via the spindle.
• Make sure that protection cap 2 and
spindle cap 1 are installed with in-
serted gasket.
Fig. 174
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 section
4.3.1 Maintenance schedule
• Use citric acid in case of furring.
• Thoroughly clean the parts with water.
Replacing or cleaning the filter element


o
separator parts (separating temperatures of 70 to 100 C (158 – 212 °F) ).

144 2063-9001-100 / 0509
• 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. 175
• 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.

2063-9001-100 / 0509 145
4.4.6 Important instructions for assembling the bowl

When the bowl has not been correctly assembled or is inadequately cleaned,
forces can be produced in the high-speed rotating bowl which endanger the
operating safety of the separator!
Therefore, the cleaning instructions (section 4.4.2) and assembling instructions
(section 4.4.7) must be exactly followed.
Pay particular attention to the following:
ATTENTION!
• Before assembling the bowl, check to be sure that the guide and contact sur-
faces of the bowl are clean.
• Grease the guide surfaces as specified in the lubrication schedule (see 4.3.4).
• Some bowl parts are arranged in

fixed positions relative to one an-
other.
• Locking devices and alignment
marks must be in perfect condition.
IMPORTANT:
The bowl must otherwise not be op-
erated.
Fig. 176
• When fitting the bowl parts, make

sure that the "O" marks on all parts
are aligned.
(Only then will the parts fit correctly
over arresting pins and guide ribs).
Fig. 177
• Avoid damage to bowl parts when fitting and removing by




146 2063-9001-100 / 0509


• If the plant has several separators,
be sure not to interchange parts of
different bowls.
The parts are marked
– with the serial number or
– the last three digits of the serial
number.
Fig. 178
• 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. 179

2063-9001-100 / 0509 147
4.4.7 Assembling bowl
• Pay special attention 4.4.2 to sections “Safety”, and 4.4.6.

• For dimensions of the parts see 4.4 - exploded view.
Install water chamber bottom

– Eye bolt 1
• Unscrew hexagon nut 2.

• Screw eye bolt 1 in bowl bottom and
firmly tighten with wrench.
Fig. 180
• Insert gaskets 1 and 2 in the water

chamber bottom grooves.
• Attach bowl bottom in the load hook
of the hoist and lift to eye level.
• The 0 mark on the bowl bottom and
water chamber bottom must be
aligned.
• Place water chamber bottom in the
bowl bottom.
• Screw in the four Allen screws 3
holding the water chamber bottom
and bowl bottom together tightly.
Torque: 30 Nm
Fig. 181

148 2063-9001-100 / 0509
• Clean the bowl hub with a suitable

cloth.
– The cone must be clean and dry.
• IMPORTANT: Do not grease the
bowl hub!

• Lower bowl bottom with built-in wa-
ter chamber bottom again.
Fig. 182
• Remove hoist and screw out eye bolt.
Installing the annular piston and the closing chamber bottom
• Grease guide surfaces as specified

in the lubrication schedule (see
4.3.4).
• Insert gasket 1 and piston guide
ring 2 into the grooves of the bowl
bottom.
Fig. 183
• For replacing the polyamide gas-

ket 1 see section 4.4.9.
• Place gasket 2 into the groove of the
annular piston and press in evenly
and firmly.
4.3.4).
Fig. 184

2063-9001-100 / 0509 149
• Insert annular piston 1 into bowl

bottom 2.
Fig. 185
• Insert guide strip 1 bit by bit into the

groove of the closing chamber bot-
tom and carefully tap it in with a mal-
let!
• Thoroughly clean guide strip 1 and
its guide surfaces.
Fig. 186
• Insert gaskets 1 and 3 in the

grooves of the closing chamber bot-
tom.
4.3.4).
Fig. 187

– Two complete assembling devices:
Hex head screw 1
Wing nut 2
Pipe 3
Hexagon nut 4
Fig. 188

150 2063-9001-100 / 0509
• Insert two assembling devices into

opposite bores of closing chamber
bottom 5 and fasten with hexagon
nuts 4.
• The “O” marks of the closing cham-
ber bottom and the bowl bottom
must be aligned.
• Insert closing chamber bottom 5 into
the annular piston by means of the
assembly devices.
Fig. 189
• Remove two hexagon nuts 4.

• Screw two assembling devices into
the bowl bottom.
• Insert the closing chamber bottom
into the bowl bottom by turning wing
nuts 2 clockwise
• Remove the assembling devices.
Fig. 190
• The “O” marks of the bowl bottom

and the closing chamber bottom
must be aligned.
• Fasten closing chamber bottom 1
onto the bowl bottom by tightening
twelve Allen screws 2 crosswise.
Fig. 191
• Screw tight the twelve Allen screws

holding the closing chamber bottom
Torque: 45 Nm
Fig. 192

2063-9001-100 / 0509 151
• Make sure that piston guide ring 1 is

firmly located in the groove.
Fig. 193
Installing the sliding piston
• Insert spindle screw 1 into the hub.
Fig. 194

groove of the sliding piston and
carefully tap it in with a mallet!
its guide surfaces.
• Insert gasket 1 in the groove of the
sliding piston.
4.3.4).
Fig. 195

152 2063-9001-100 / 0509
• Grease the thread of sliding piston 1

(see chapter 4.3.4).
• Screw bell-shaped piece 3 of the
compressing device into the thread
of the sliding piston.
• Screw bolt unit 2 into the sliding
piston, through the bell-shaped
piece.
Fig. 196

• Install the sliding piston (with fitted
gasket) into the bowl bottom using
compressing device and hoist.
• Remove the hoist and unscrew the
bolt unit.
Fig. 197
• Unscrew spindle screw 1.
Fig. 198
• Place disk 1 onto the bell-shaped

piece.
• Screw the complete eye bolt 2 into
the bowl hub as far as it will go.
• Press the sliding piston into its seat,
as far as it will go, by turning the
hexagon nut clockwise with an
open-ended wrench.
• Remove the tools.
Fig. 199

2063-9001-100 / 0509 153
Installing the distributor and disk stack
IMPORTANT: Pay attention to the

required total number of disks!
This is indicated 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. 200
IMPORTANT: The last disks must be

correctly inserted in the guide fins
of the distributor!
• Carefully stack the disks on the dis-

tributor neck.
Fig. 201
• Screw the bolt unit of the compress-

ing device into the distributor with
the wrench as far as possible.
Fig. 202

154 2063-9001-100 / 0509

• Install the distributor together with
the disk stack using the bolt unit and
hoist.
• The 0 marks on the bowl bottom and
disk stack must be aligned.
• Pay attention to correct positioning!

unit.
Fig. 203
Installing the separating disk
• Place the separating disk on the

distributor neck.
Fig. 204
Installing the bowl top
• Thoroughly clean the grooves for

gaskets 1 and 2 in the bowl top.
• Check gaskets 1 and 2:
– replace when damaged,
– install if missing.
• For replacing the polyamide gasket
3 see section 4.4.8.
Fig. 205

2063-9001-100 / 0509 155

Compressing device
– Bolt unit 1
– Bell-shaped piece 2
Fig. 206
Bolt unit 1 comprises ring nut, lever, and bolt.

– The ring nut must always be screwed into the bolt and be secured with Loc-
tite 275.
– The lever must always have smooth impingement surfaces (deburr if neces-
sary).
• Grease the thread of the bowl top

(see chapter 4.3.4).
• Place bell-shaped piece 2 on the
bowl top.
• The “O” marks of the bell-shaped
piece and the bowl top must be
aligned.
• Screw on centripetal pump chamber
hand thread).
• Screw in bolt unit completely into the
bell-shaped piece.
Fig. 207

• Install the bowl top using bolt unit
and hoist.
• The "O" marks must be aligned.
• Remove the hoist.
Fig. 208

156 2063-9001-100 / 0509
Compressing the disk stack

shaped piece and thread it into the
distributor as far as it will go, using
an open-ended wrench.
Fig. 209
IMPORTANT: Prevent seizing of

threads!
• The following parts must be carefully
cleaned, wiped dry and greased in
accordance with the lubrication
schedule (see 4.3.4).
– threads and guide surfaces of
bowl bottom and lock ring
– contact surfaces of bowl top and
bowl lock ring
Fig. 210

• Hold bowl lock ring together with

ring spanner and gradually lower
them onto the bowl bottom using
chains and hoist.
• Screw the bowl lock ring by hand
into the thread of the bowl bottom
as far as possible (left-hand
thread).
Fig. 211
• Remove hoist and chains.

2063-9001-100 / 0509 157
• Screw on the lever until it rests on

the bell-shaped piece.
through rotating lever!
• Firmly hit the lever with the mallet.
– The disk stack is thus com-
pressed.
Fig. 212

through the lever!
• Strike the bowl lock ring with a mal-
let until the "O" mark is reached
(left-hand thread).
CAUTION:
Fig. 213
• Remove centripetal pump chamber lock ring, compressing device and com-
pressing device.
• Screw in two threaded pins.
Fig. 214

158 2063-9001-100 / 0509
Installing the complete bowl and the centripetal pump
• Clean and wipe dry the spindle

cone with a suitable cloth.
IMPORTANT:
Do not grease the conical parts!
Fig. 215

– Eye bolt 1
• Unscrew hexagon nut 2

• Screw eye bolt 1 completely into the
bowl bottom.
Fig. 216

• Carefully place the bowl using eye
bolt and hoist on the spindle cone.
Fig. 217

2063-9001-100 / 0509 159
• Unscrew the eye bolt from the bowl

bottom.
Fig. 218
Required tools
– Socket wrench
– Torque wrench
• Provide spindle screw 2 with gas-

ket 1.
• Put spindle screw into socket
wrench and screw in (left-hand
thread).
Fig. 219
CAUTION:
A loose spindle screw can endanger
life!
• Tighten spindle screw.

Torque: 80 Nm
Fig. 220
• Check that spindle and bowl are

centred.
The control dimension B
– is 5 ±1,5 mm
– between the bowl and the upper
section of the frame.
• Pay attention to bowl height A (see

section 4.7.1).
Fig. 221

160 2063-9001-100 / 0509

grooves of the bowl top.
Fig. 222
• Insert gasket 1 in the centripetal

pump groove.
• Lightly grease threads and contact
surfaces of the centripetal pump.
• Install centripetal pump 2.
Fig. 223
• Mount the centripetal pump chamber

cover.
• The 0 mark on the centripetal pump
chamber cover and bowl bottom
must be aligned.
• Pay attention to correct positioning.
Fig. 224
• Insert the gasket in the groove of the

centripetal pump chamber cover.
Fig. 225

2063-9001-100 / 0509 161
• Insert gaskets 1 and 2 in the sensing

liquid pump grooves.
• Grease guide surfaces.
• Install sensing liquid pump.
Fig. 226
• Mount the centripetal pump chamber

cover.
• The “O” marks of the centripetal
pump chamber cover and the bowl
bottom must be aligned.
Fig. 227
• 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 ring
spanner (left-hand thread).
Fig. 228
• Pay attention to section 4.7.1.

162 2063-9001-100 / 0509
4.4.8 Replacing the polyamide gasket (bowl top)

• For standard tools, see section 4.13.
REMOVAL
IMPORTANT: Fragile bowl part!
– Do not damage the bowl top groove
when drilling!
• Drill through the damaged polya-

mide gasket twice centrically and
vertically.
– with a 2 mm drill bit
– at a distance of approx. 50 to
60 mm.
Fig. 229
IMPORTANT: Fragile bowl part!

– Do not damage the bowl top groove
while screwing!
• Screw two wooden screws in the
holes in the polyamide gasket.
• Force off the old polyamide gasket
with the wood screws.
• Lever it out of the groove bit by bit
using a screwdriver.
Fig. 230
Note:
If the polyamide gasket can’t be removed, repeat this procedure.
FITTING
• Thoroughly clean and dry the groove.
o
• Heat the gasket in approx. 80 C (176 °F) water for 5 minutes.
• Wipe dry the gasket.
• Fit the gasket into the groove of the

bowl top (with the narrow side facing
the bowl top).
• Place on a wooden block.
• hammer the gasket evenly into the
groove.
Fig. 231

2063-9001-100 / 0509 163
• The sealing surface of the gasket

must not protrude by more than 0.5
mm from the surface "A" of the bowl
top.
Fig. 232

164 2063-9001-100 / 0509
4.4.9 Replacing the polyamide gasket (bowl top)

Change the polyamide gasket only when it is damaged.
• For standard tools, see section 4.13.
REMOVAL
IMPORTANT: Sensitive bowl part!

– Do NOT damage the ring 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 approx. 50 to
60 mm.
Fig. 233
IMPORTANT: Sensitive bowl part!

– Do NOT damage the ring piston
groove when screwing in!
• Screw two wooden screws in the
holes in the polyamide gasket.
• Force off the old polyamide gasket
with the wood screws and
• lever it bit by bit out of the groove
using a screwdriver.
Fig. 234
Note:
If the polyamide gasket can’t be removed, repeat this procedure.

2063-9001-100 / 0509 165
FITTING
• Thoroughly clean and dry the

groove.
• Heat the new polyamide gasket in
o
approx. 80 C (176 °F) water for 5
minutes.
• Wipe the gasket dry and press it
evenly and firmly into the groove, at
four opposite points
Fig. 235
• Insert annular piston 1 into bowl

bottom 2.
Fig. 236

groove of the closing chamber bot-
tom and carefully tap it in with a mal-
let!
its guide surfaces.
Fig. 237

166 2063-9001-100 / 0509

grooves of the closing chamber bot-
tom.
4.3.4).
Fig. 238
• Clamp mounting ring 1 under the rim

of the closing chamber bottom.
Fig. 239

– Two complete assembling devices:
Hex head screw 1
Wing nut 2
Pipe 3
Hexagon nut 4
Fig. 240
• Insert two assembling devices into

opposite bores of closing chamber
bottom 5 and fasten with hexagon
nuts 4.
• The O marks of the closing chamber
bottom and the bowl bottom must be
aligned.
• Insert closing chamber bottom 5 into
the annular piston by means of the
assembly devices.
Fig. 241

2063-9001-100 / 0509 167
• Remove two hexagon nuts 4.

• Screw two assembling devices into
the bowl bottom.
• Insert the closing chamber bottom
into the bowl bottom by turning wing
nuts 2 clockwise
• Remove the assembling devices.
Fig. 242
• The O marks of the bowl bottom and

the closing chamber bottom must be
aligned.
• Fasten closing chamber bottom 1
onto the bowl bottom by tightening
twelve Allen screws 2 crosswise.
Fig. 243
• Screw tight the twelve Allen screws

holding the closing chamber bottom
Torque: 45 Nm
Fig. 244
• Insert spindle screw 1 into the hub.
Fig. 245

168 2063-9001-100 / 0509
• Unscrew the twelve Allen screws

holding the bowl bottom and the
closing-chamber bottom together.
Fig. 246

– Compressing device
Bolt unit 1
Bell-shaped piece 2
Fig. 247
• Insert bell-shaped piece 1 into the

bowl bottom.
• Fit assembling device 2 onto bell-
shaped piece 1.
• Loosen three Allen screws 3 using
the ratchet wrench (with extension
and socket).
• Slip three disks 4 of the assembling
device towards the periphery, under
the rim of annular piston 5.
• Make sure that disks 4 are properly
positioned under the annular piston.
Fig. 248 • Firmly re-tighten Allen screws 3.
• Screw bolt unit 1 into bell-shaped

piece 2
• Force off closing chamber bottom 3
together with annular piston 4 by
turning the bolt unit clockwise.
Fig. 249

2063-9001-100 / 0509 169

• Lift out closing chamber bottom 3
and annular piston 4 (with fitted gas-
kets) using the hoist.
Fig. 250
• Separate annular piston 1 from clos-

ing chamber bottom 2 by tapping
with a mallet – as illustrated.
Fig. 251
• Remove the mounting ring.
Fig. 252
• Unscrew spindle screw 1.
Fig. 253

170 2063-9001-100 / 0509
• 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. 254

2063-9001-100 / 0509 171
4.4.10 Reworking the sliding piston

The bowl seal consists of
• sealing surface A of the sliding piston (Fig. 255) (new condition of the sliding
piston rim H: 35 mm high) and
• polyamide gasket B of the bowl top (Fig. 256).
When worn, the sealing surface A of

the sliding piston can be remachined
up to max. 1,0 mm several times
before it has to be replaced.
ATTENTION! When the first erosion

marks (0.2 to 0.3 mm deep) are de-
tected, i.e. as soon as the bowl
starts to leak:
• Remachine the sealing surface of
the sliding piston.
Fig. 255
• When remachining, make sure that

– the sealing surface A is machined cleanly and
– the sliding piston rim H is still at least 34 mm high.
Standard parameters for remachining the sealing surface A

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/lrevolution
ATTENTION! After facing

• fit a new polymide gasket B into the
bowl top (see section 4.4.8)!
Fig. 256

172 2063-9001-100 / 0509
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. 257
CAUTION: Danger of injury!

• Unlock the shackle.
• Carefully close the hood.
Fig. 258
• Screw in four hex head screws (M

12 x 50) with washers.
Fig. 259

2063-9001-100 / 0509 173
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-
fied in the lubrication schedule (see
4.3.4).
Fig. 260

– Socket wrench 2
• Introduce handle connection piece 1

into the hood.
• Hold the centripetal pump with the
socket wrench and screw in by
lightly hammering the handle con-
nection piece with a mallet (left
hand thread).
Fig. 261
• Carefully clean the holes in the non-

return valve and
• rinse with water.
• Check the functionality of the non-
return valve.
Fig. 262
• Assemble and connect filling and

displacement water feed line 1.
Fig. 263

174 2063-9001-100 / 0509
4.6 Drive
Fig. 264 Exploded view of the drive

2063-9001-100 / 0509 175
Pos. Designation Dimensions
- Neck bearing bridge, compl.

10.1 Neck bearing bridge:
10.2 Neck bearing pressure ring
10.3 Threaded plug
10.4 Set of neck bearing springs
10.5 Spring piston
20 Gasket
30 Pivoting bearing
40 Bearing housing
50 Gasket
60 Washer 12.5 x 22 x 1
70 Hex head screw M 12 x 40
75 Lock washer
- Spindle assembly
80.1 Spindle
80.2 Neck bearing protection cap
80.3 Spacer ring
80.4 Cylindrical roller bearing
80.5 Set collar
80.6 Threaded pin
80.7 Ball bearing protection ring
80.8 Angular contact ball bearing
80.9 Bearing sleeve
80.10 Cylindrical pin
80.11 Dowel pin
95 Lock washer
- Centrifugal clutch, compl.
100.1 Clutch pulley
100.2 Grooved ball bearing
100.3 Distance sleeve
100.4 Retaining ring 95 x 3
100.5 Clutch driver
100.7 Flat belt pulley
100.8 Allen screw M 10 x 35
100.9 Clutch shoe
100.10 Washer
110 Washer
130 Drive belt

176 2063-9001-100 / 0509
4.6.1 Important instructions for fitting and removing the drive


still.
(without braking!).

sight glass.
no longer moving.
Fig. 265


still.
separator!

o

2063-9001-100 / 0509 177


Germany in accordance with the rules and regulations of the VDE (Verband
Deutscher Elektrotechnik/ Association of German Electrical Engineering) or of
only.
• Avoid damage to drive parts when fitting and removing by




• Treat all drive parts
– gently.
– Always set them down on a rubber mat or a wooden pallet.
IMPORTANT: 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!
• Check the ball bearings of the spindle and centrifugal clutch.
Use only the ball bearings specified in the parts list!
IMPORTANT: To avoid bearing damage,

• always operate the separator with installed bowl!

178 2063-9001-100 / 0509
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.
3,7 l).
Fig. 266
• Undo three hex head screws 1.

• Remove the brake with brake hous-
ing 2.
Fig. 267
• Unscrew four hex head screws 1.
Fig. 268

2063-9001-100 / 0509 179
• Pull the motor out of the flange

guide by means of the hoist (approx.
10 mm).
– Drive belt is slackened!
ATTENTION!
• Pull the drive belt off the belt pulley
(centrifugal clutch) downwards.
Fig. 269
• Lift the motor with centrifugal clutch

out of the lower section of frame.
Fig. 270
Remove the operating water con-

nection in the upper section of
frame:
• Undo nut 2.
• Take off pipe 3.
Fig. 271
• Remove spindle cap 1 with fitted

gasket.
Fig. 272

180 2063-9001-100 / 0509
• Undo six hex head screws 1.

• Remove ring 2 and protective cap 3
with inserted gasket 4.
Fig. 273
Removing the speed monitoring

device:
• Unscrew hex head screw 1.
• Take off speed monitoring device 2
and lay it down in the lower section
of frame.
Fig. 274
• Take the drive belt out of the lower

section of frame.
Fig. 275
• Unscrew the three hex head screws

1 with lock washers 2.
• Unscrew spindle assembly 3 from
the lower section of the frame.
(For dismantling the spindle assem-
bly, see section 4.6.3.)
Fig. 276

2063-9001-100 / 0509 181
Required tools:
– Three hex head screws 1
(M 12 x 75)
• Thread hex head screws 1 into the

puller holes.
• Force the neck bearing bridge 2 off
the frame by turning the screws 1
clockwise.
Fig. 277
ATTENTION!
Before dismantling the neck bearing
bridge,
• mark the side of the neck bearing
A bridge facing the motor.
A Motor side
Fig. 278
• Remove the neck bearing bridge

with neck bearing pressure ring from
(For dismantling the neck bearing
bridge, see section 4.6.7.)
Fig. 279
• Unscrew the four hex head screws 1

with lock washers 2.
Fig. 280

182 2063-9001-100 / 0509
Required tools:
– Two hex head screws 2 (M 10 x 40)
• Force off bearing housing 1 by turn-

ing hex head screws 2.
• Remove the bearing housing from
the lower section of frame together
with pivoting bearing 3, washers 4
and inserted gasket 5.
Fig. 281

2063-9001-100 / 0509 183
4.6.3 Dismantling the spindle assembly
Spindle assembly
Fig. 282
Required tools:
– commercially available pulling de-
vice
– open ended wrench
• Pull off from the spindle:

– cylindrical pin 1
– heat bearing sleeve 2
– angular contact ball bearing 3
– ball bearing protection ring 4
Fig. 283

184 2063-9001-100 / 0509
Required tools:
– Mallet
IMPORTANT: Sensitive material!

– Be careful not to damage the spin-
dle.
• Drive the dowel pin 1 out of the

spindle by means of light hammer
blows.
Fig. 284
• Unscrew threaded pin 1 from the set

collar 2 and
• detach the set collar 2 from the
spindle.
Fig. 285
Required tools:
– commercially available pulling de-
vice
– open ended wrench
• Pull off from the spindle:

– cylindrical roller bearing 1,
– spacer ring 2,
– neck bearing protection cap 3.
Fig. 286

2063-9001-100 / 0509 185
4.6.4 Dismantling the centrifugal clutch
• Undo three hex head screws 1.

• Remove the brake with brake hous-
ing 2.
Fig. 287
• Unscrew four hex head screws 1.
Fig. 288
• Pull the motor out of the flange

guide by means of the hoist (approx.
10 mm).
– Drive belt is slackened!
ATTENTION!
• Pull the drive belt off the flat belt
pulley (centrifugal clutch) down-
wards.
Fig. 289

186 2063-9001-100 / 0509

• Lift the motor with fluid clutch out of
Fig. 290
• Turn the motor together with the

o
centrifugal clutch 90 (upside down)
with the aid of the hoist.
• CAUTION: Secure from rolling
away and overturning using suit-
able aids!
Fig. 291
• Undo retaining ring 1.

• Take off disk 2.
Fig. 292
• Pull the clutch shoes out of the

clutch driver.
Fig. 293

2063-9001-100 / 0509 187
• Arrest the clutch driver 1 with an

open-ended wrench.
• Unscrew hex head screw 2 from the
motor shaft end.
• Take off disk 3.
Fig. 294
Required special tools:

– Threaded pin 2 = M 16 x 50

open-ended wrench.
ATTENTION! For protecting the mo-
tor shaft end:
• Screw threaded pin 2 into the thread
of the motor shaft end.
Fig. 295
Required special tool:

– Hex head screw (M 30 x 240)
• Screw the hex head screw into the

clutch driver.
• Arrest the clutch driver with an open-
ended wrench.
• Force the centrifugal clutch off the
motor shaft end by turning the hex
head screw clockwise.
Fig. 296
• Remove hex head screw 1 from the

clutch driver and threaded pin 2 from
the motor shaft end.
Fig. 297

188 2063-9001-100 / 0509

• Place the clutch pulley with fitted flat
belt pulley and clutch driver on a
wooden base using transport ropes
and hoist.
able aids!
• Take the retaining ring out of the
clutch driver groove.
Fig. 298
• Position wooden block.

• Drive the clutch driver downwards
by means of light hammer blows.
• Loosen the clutch driver from the
seat of the two ball bearings.
Fig. 299
• Turn the clutch pulley together with

o
fitted flat belt pulley 90 (upside
down) with the aid of the hoist.

able aids!
• Take the retaining rings out of the

clutch drum grooves.
Fig. 300
Required tools
– Disk (Ø 86 – 94 mm)
– Wooden block
– Hammer
• Turn the clutch pulley with fitted flat

o
belt pulley through 180 and
• place it on wooden supports as
shown.
• Drive the grooved ball bearing and
spacer bush out of the clutch pulley.
Fig. 301

2063-9001-100 / 0509 189
4.6.5 Fitting the spindle assembly
• Pay special attention to section 4.6.1

• For dimensions of the parts see 4.6 - exploded view.
• Insert gasket in groove of bearing

housing.
Fig. 302
• Screw bearing housing 1 together

with pivoting bearing 2 into place
with the four hex head screws 3,
lock washers 4 and washers 5.
• For number of washers, refer to
section 4.7.1.
Fig. 303
• Ensure correct assembly of neck

bearing bridge (section 4.6.7).
• Provide neck bearing bridge 1 with
gaskets 2.
correct fitting position of the neck
bearing bridge!
– The holes in the neck bearing bridge
must be aligned with the holes in
• Fit in the neck bearing bridge 1 with
the marked side facing the motor.
Fig. 304

190 2063-9001-100 / 0509
Note:
When the drive belt is dismantled, torn
or not tensioned, the neck bearing
pressure ring 1 is eccentric relative to
A the side facing away from the motor in
the neck bearing bridge.
The neck bearing pressure ring 1 is
pulled into the centric axis when the
belt is tensioned!
A = Motor side
Fig. 305
o
• Turn spindle through 180 (upside
down).
• Mount neck bearing protection cap 1

and spacer ring 2.
correct fitting position of spacer
ring 2!
– The small inner diameter of the
spacer ring must be directed to the
neck bearing protection cap 1.
Fig. 306
o o
• Heat cylindrical roller bearing 3 in oil up to 100 C (212 F) and slip it onto the
spindle.
• Slide set collar 4 on to the spindle and secure it in the spindle groove with four
threaded pins.
Required tools:
– Mallet
IMPORTANT: Sensitive material!

– Be careful not to damage the spin-
dle.
• Install dowel pin 1 dead centre by

hammering lightly.
Fig. 307

2063-9001-100 / 0509 191
• Heat ball bearing protection ring 1

and angular contact ball bearings 2
o o
in oil up to 100 C (212 F).
ATTENTION: Bearing damage is
caused by incorrect fitting!
– When fitting angular contact ball
bearings 2 on the spindle, make
sure that the narrow rim of each
ball bearing inner ring faces up-
wards.
• Slide ball bearing protection ring 1
and angular contact ball bearings 2
Fig. 308 onto the spindle.
• Fit cylindrical pin 1 in the bearing

sleeve and secure with Loctite 275.
• Heat bearing sleeve 2 in oil up to
o o
100 C (212 F).
• Important! Before fitting bearing
sleeve 2, make sure that the in-
stalled angular contact ball bearings
have cooled down to room tempera-
ture.
• Slide bearing bush 2 over the angu-
lar contact ball bearings and the ball
bearing protection ring.
Fig. 309
• Install the assembled spindle as-

sembly 1 in the lower part of the
frame.
Pay attention to correct positioning!
ATTENTION: Pay attention to the
correct fitting position of the spin-
dle!
– The holes in the bearing cover must
be aligned with the holes in the
lower section of the frame.
• Screw tight the spindle with the
three hex head screws 2 and lock
Fig. 310 washers 3.
• Place drive belt on the spindle.
Fig. 311

192 2063-9001-100 / 0509
4.6.6 Fitting the centrifugal clutch
• Pay special attention to section 4.6.1

• For dimensions of the parts see 4.6 - Exploded View.
• Clean clutch pulley 1 with fitted flat

belt pulley 2.
• Insert retaining ring 3 in the lower
groove.
• Check that retaining ring 3 is cor-
rectly fitted.
Fig. 312
Required tools:
– Disk 2 (Ø 86 – 94 mm)
– Wooden block
– Hammer

– Disk 2 may only contact the outer
ring of grooved ball bearing 1!
• Carefully drive the first grooved ball

bearing 1 with disk 2 up to the re-
taining ring.
Fig. 313

2063-9001-100 / 0509 193

• Carefully drive the second grooved

ball bearing 1 with disk 2 up to the
first grooved ball bearing.
Fig. 314

– Distance sleeve 1 may only contact
the inner ring of grooved ball bear-
ing 2!
• Place distance sleeve 1 on the ball

bearing inner ring.
Fig. 315

194 2063-9001-100 / 0509
ATTETNION: Bearing damage is

• Carefully drive the third grooved

ball bearing 1 with disk 2 up to the
distance sleeve.
CAUTION: Danger of imbalance by

incorrect fitting!
o
• Insert retaining ring 2 180 offset
relative to retaining ring 1 in the up-
per groove.
Fig. 316

2063-9001-100 / 0509 195
Required tools:
– Disk 1 (Ø 61 – 69 mm)

• Turn clutch pulley with fitted flat belt
pulley and installed grooved ball
o
bearings through 180 .
Fig. 317
ATTENTION: Bearing damage is caused by incorrect fitting!

– Disk 1 may only contact the inner ring of the grooved ball bearing!
• Place the ball bearing inner ring on disk 1.

correct fitting position of the dis-
tance sleeve!
– Distance sleeve 1 must be flush with
the inner rings of the grooved ball
bearings.
Fig. 318
Required tools:
– Wooden block
– Rubber hammer
• Carefully hammer the clutch driver

into the grooved ball bearing with
light blows.
Fig. 319

196 2063-9001-100 / 0509
• Turn clutch pulley with fitted flat belt

pulley and fitted clutch drive through
o
180 with the aid of the hoist.
• Fit the retaining ring in the groove of
the clutch driver.
Fig. 320

o
• Turn the motor through 90 with the
aid of the hoist.
able aids!
Fig. 321
Required tools:
– Hex head screw 3 (M 16 x 250)
– Hexagon nut 4 (M 16)
• IMPORTANT: Pay attention to the

feather key groove.
• Fit the assembled centrifugal clutch
on the motor shaft end.
open-ended wrench.
• Insert assembling device 2 - as
shown - and
• screw hex head screw 3 with hexa-
gon nut 4 into the motor shaft end.
Fig. 322

2063-9001-100 / 0509 197
• Pull the centrifugal clutch onto the

motor shaft end as far as it will go,
by turning hexagon nut 4 with a sec-
ond open-ended wrench.
Fig. 323
• Undo hex head screw 3 together

with hexagon nut 4 and
• Remove assembling device 2.
Fig. 324
IMPORTANT: With driver 1 arrested:

• Provide hex head screw 2 (M 16x65)
with washer 3 and thread it into the
motor shaft end.
Fig. 325

– Be sure to replace all clutch shoes
simultaneously!
Never replace individual clutch
shoes.
– Make sure that the clutch shoes are
evenly spaced!
• Fit clutch shoes.
Fig. 326

198 2063-9001-100 / 0509
• Insert disk 1.
• Fit the retaining ring 2 in the groove
of the clutch driver.
Fig. 327

2063-9001-100 / 0509 199
4.6.7 Replacing the neck bearing springs (neck bearing bridge)
The neck bearing springs 2 are ex-

posed to different stresses due to the
drive belt tension (stronger stress on
the motor side A of the neck bearing
A bridge).
To check the condition of the neck
bearing springs 2,
• they must be dismantled periodically
(see section 4.3.1) and individually
(see Fig. 329).
• and their length measured (see Fig.
330) dimension A).
Fig. 328
• Dismantle threaded plug 1, neck

bearings 2 and spring piston 3 from
the marked motor side of the neck
bearing bridge.
Fig. 329
• Check neck bearing spring 2 for

deformation.
Neck bearing spring – New con-
dition:
A = 32 ±0.4 mm
Neck bearing spring –
Deformation limit:
A = 31 mm
• If dimension “A” is below the de-

formation limit:
Fig. 330
– Replace neck bearing springs ac-
cording to Fig. 331 in the neck
bearing bridge.

200 2063-9001-100 / 0509
• Replace the neck bearing springs

H1 of the strongly stressed motor
side A with the neck bearing springs
H2 of the less stressed side of the
neck bearing bridge – as illustrated.
A • To fit the neck bearing springs refer
to Fig. 332.
Fig. 331
• Coat spring piston 3 liberally with

grease.
• Insert the neck bearing springs 2 in
the spring pistons 3.
• Fit threaded plug 1.
• Screw threaded plug 1 together with

neck bearing spring 2 and spring
piston 3 into the taphole of the neck
bearing spring and tighten.
Fig. 332
Note:
Do not forget to order a new set of neck bearing springs from Westfalia Separa-
tor!
The deformed neck bearing springs must be replaced after 8000 operating
hours.
Dismantling the complete neck bearing bridge
• Remove six threaded plugs 1, neck

bearing springs 2 and spring pistons
3.
• Lift neck bearing pressure ring 4 out
of neck bearing bridge 5.
Fig. 333

2063-9001-100 / 0509 201
Assembling the complete neck bearing bridge

Note:
The spindle cylindrical roller bearing is inserted into neck bearing pressure ring
4, which is held in position by a radial arrangement of six evenly distributed
springs 2.
• Install neck bearing pressure ring 4

the neck bearing bridge 5.
IMPORTANT: The six recesses of
the pressure ring must be located at
the six holes in the neck bearing
bridge!
• Coat spring piston 3 liberally with
grease.
• Insert the neck bearing springs 2 in
the spring pistons 3.
• Fit threaded plug 1.
Fig. 334
• Screw the six threaded plugs 1 together with the neck bearing springs 2 and
spring pistons 3 into the six tapholes of the neck bearing bridge 5 and tighten.

202 2063-9001-100 / 0509
4.6.8 Fitting the motor
• Carefully place the motor with pre-

assembled centrifugal clutch on the
lower section of frame by means of
a hoist.
– Do not yet let the motor flange
lock into the frame opening.
Fig. 335
IMPORTANT:
• Degrease the belt contact surfaces
of the spindle and clutch drum.
• Fit the drive belt:
– through upper section of frame
opening 1 and
– through brake housing opening 2
(centrifugal clutch).
• Pay attention to correct seating of
the drive belt on flat belt pulley and
spindle pulley.
Fig. 336
• Unscrew the screw plug 1 from the

lower part of the frame.
Fig. 337

2063-9001-100 / 0509 203
• Screw the complete clamp bolt

through the hole in the frame and
into tapped hole of centrifugal clutch
as shown.
• IMPORTANT: To avoid damage to
the grooved ball bearing:
– do not screw in hex head screw 1
all the way.
• Tension the drive belt by turning hex
head nut 2 clockwise until the mo-
tor flange locks into the frame open-
ing.
Fig. 338
• Fasten the motor with four hex head

screws 2 (M 16 x 40).
• IMPORTANT: Unscrew complete
clamp bolt 1 out of the centrifugal
clutch again.
Fig. 339
• Screw in the screw plug 1.

• Remove the hoist.
Fig. 340
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. 341, pos. 2).
The spindle is pulled into the centric axis when the belt is tensioned (see Fig.
341, pos 1)!

204 2063-9001-100 / 0509
• Check
– that the spindle 1 can be turned
easily.
– whether spindle 3 has been
pulled into the centric axis by
tensioning drive belt 3 (see Fig.
221).
Fig. 341
Installing the speed monitoring de-

vice:
• Place speed monitoring device 2 on

the lower section of frame and
• fasten with hex head screw 1.
Fig. 342
• Align proximity switch 1 as illus-

trated.
ATTENTION!
The distance X between the spindle
and the proximity switch must be 2.5
mm.
Fig. 343
• Insert protective cap 3 with fitted

gasket 4 and ring 2 and
• Fasten with six hex head screws 1
(M 8 x 16).
Fig. 344

2063-9001-100 / 0509 205
• Place spindle cap 1 with fitted gas-

ket on the spindle.
Fig. 345
Fitting the operating water connec-

tion in the upper section of frame:
• Slide nut 2 over pipe 3.
• Fit pipe with nit into the screwed
connection 1 and slide on as far as it
will go.
IMPORTANT: The narrow end of the

pipe must be directed upwards!
• Tighten nut 2 firmly.
Fig. 346
• Fit brake and brake housing 2 to the

lower section of the frame with three
hex head screws 1 (M 8 x 20).
Fig. 347
• Screw in oil drain screw 1 with fitted

gasket.
• Screw in the sight glass 2.
• Fill in oil as described in section
4.3.3 and
• Screw in plug 3 with gasket.
Fig. 348

206 2063-9001-100 / 0509
Danger to life and limb through electric current!

• Have the motor connected by an authorized electrician!

2063-9001-100 / 0509 207
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

The bowl height is correctly adjusted at the factory before shipment of the sepa-
rator.
IMPORTANT: The bowl height may only be measured with installed and
tensioned drive belts!
CHECKING
Check the bowl height and readjust if 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:
• Firmly tighten bowl lock ring.

– The "O" marks on the bowl bottom
or top and on the bowl lock ring
must be aligned.
Fig. 349
The control dimension A

– is 18 ±2 mm
– between upper edge of bowl lock
ring and upper section of frame.
Fig. 350

208 2063-9001-100 / 0509
ADJUSTING
Bowl too high Increase number of washers 3.
Bowl too low Reduce number of washers 3.
Washer:
Inner diameter, 12.5 mm – outer diameter, 22 mm – thickness, 1 mm
CAUTION: Danger of crushing by

falling separator parts!
• Four hex head screws 1 of bearing
housing 2 must be
– unscrewed evenly and in di-
agonal sequence (do not re-
move!);
– loosen until a gap A is created for
the required number of washers 3
between the lower section of the
frame and the bearing housing.
Fig. 351
• Remove hex head screw 1 indivi-

dually and
• add or remove washer(s) 3.
• Screw in hex head screw 1 again.
• Remaining hex head screws 1 must
be:
– removed individually
– fitted with the same number of
washers 3 and
– screwed in again.
Fig. 352
• Screw bearing housing 2 tightly into

place via the four hex head screws 1
with the necessary washers 3.
• Check bowl height.
Fig. 353

2063-9001-100 / 0509 209
4.7.2 Centripetal pump clearance
• Move the centripetal pump axially to

and fro in the centripetal pump
chamber.
• Measure the total clearance A (ap-
prox.10 mm) .
• Close the hood.
• Check:
– Is the hood correctly seated on
the frame rim?
– Are the hood screws tightened
firmly?
Fig. 354
• 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 sock-
et wrench 2.
• Screw handle connection piece into
the centripetal pump as far as it will
go (left-hand thread).
Fig. 355
• Hold the handle connection piece 1.

• Turn the socket wrench 2 until the
handle connection piece is raised
slightly from the hood (approx. 0.5
mm).
Fig. 356

210 2063-9001-100 / 0509
• Raise the handle connection piece

to its maximum.
• Measure the axial clearance.
A/2 = 4 – 6 mm
Fig. 357
Check:
• Axial clearance too large:
– Lift off the bowl, see section 4.7.1 - Adjustment.
• Axial clearance too small:
– Lower the bowl, see section 4.7.1 – Adjustment.

2063-9001-100 / 0509 211
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:
Checks Section
1. Bowl height 4.7.1
2. Oil level in drive chamber 4.3.3
3. Direction of rotation of the bowl 4.1.4
4. Bowl speed 4.1.5
5. Starting time of bowl / current consumption 4.1.5
6. Running characteristics of the separator 3.8.1
7. Suction line of the product pump (if installed) for leakage
When starting the separator

Perform the following checks after carrying out repairs:
Checks Section
1. Temperature of product
2. Observe discharges for water, solids and oil to see if the 3.3
bowl is operating 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.
• 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.

212 2063-9001-100 / 0509
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.

2063-9001-100 / 0509 213
4.10 Storage
ATTENTION!
Improper and incorrect storage of the separator and control unit can dam-
age or destroy their components.
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.
IMPORTANT:
• Outdoor exposure is not admissible!
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 to +50 °C (41 – 122 °F)
IMPORTANT:
A storage time of more than 12 months of the separator and control unit is only
possible after consulting the manufacturer.
4.10.2 Separator
The following procedure applies
– for storing the separator before commissioning and
– for storing the separator before a prolonged standstill period.
IMPORTANT:
• Store the separator with dismantled bowl!
• Store the clean, greased bowl in a dry place.

• Store the gaskets in a cool, dry, frost-free, dust-free dark room to prevent
them from becoming brittle.
Recommended storage temperature: + 5 to +50 °C (41 - 122 °F)
• The separator with dismantled bowl must be stored dry and free from vibra-
tions.
(Vibrations during standstill can cause bearing damage!).
• Protect the drive spindle and motor from dust.
• 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!

214 2063-9001-100 / 0509
Recommended storage temperature: + 5 to + 45 °C (41 – 113 °F)
4.11 Before restarting
Before re-starting, the operator must ensure

• that all separators and plant components have been function-checked
by competent personnel (qualified specialists).
• that the maintenance intervals are adhered to.
• that the separator is assembled correctly by competent persons.
Note:
If the bowl has been out of operation for longer than 6 months (e.g. due to a
long standstill period or storage),
• check all bowl parts as specified in the maintenance schedule (table “Mainte-
nance after 4000 operating hours or after 6 months at the latest”).
If the separator has been out of operation for longer than 12 months (e.g. due
to a long standstill period or storage),
• check all separator parts in accordance with the maintenance schedule (table
“Maintenance after 8000 operating hours or after 1 year at the latest).
Procedure:
• Drain the slushing oil.
Observe the local regulations on disposal of the slushing oil.
• Remove the grease from all unpainted machine parts.
• Check gaskets.
Replace damaged, very swollen, hardened or brittle gaskets immediately.
• Assemble the bowl (see section 4.4.7).
• Check the ball bearings of the spindle and centrifugal clutch (if applicable).
When damaged, replace the ball bearings immediately !
• Fit drive belt (see section 4.6.5 or 4.6.8).

When damaged, replace the drive belt immediately !
• Assemble the separator correctly.

• Fill the drive chamber with the specified lube oil as specified in section 4.3.3.

2063-9001-100 / 0509 215
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
accordance with local regulations.
Note:
Fig. 358
Special attention must be paid to
the directive issued by the operator
on handling waste oils and the local
regulations.

216 2063-9001-100 / 0509
4.12.2 Cleaning liquids

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.
Note:
Pay particular attention to the directive issued by the operator on handling the
cleaning agents used and the local disposal regulations.
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.

2063-9001-100 / 0509 217
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note

218 2063-9001-100 / 0509
4.13 Standard tools

are commercially available tools to be supplied by the customer.
Fig. 359

2063-9001-100 / 0509 219
Pos. Designation
1 Screwdriver
2 Torque wrench (0 - 100 Nm)
with inserts and extension
3 Caliper 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 tachometer
10 Wrench, adjustable
11 Brushes
12 Puller (400 x 300 mm (H x W))
13 Wrench (jaw span: 19, 32, 65 mm)
14 Wooden blocks
15 Drill
16 Drill bit (Ø 2 mm)
17 Wooden screws (max. Ø 4 mm x 70 mm length)
18 Hex head screws ( M 10 x 80)
19 Chains

220 2063-9001-100 / 0509
4.14 Special tools
Fig. 360

2063-9001-100 / 0509 221
• 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 Socket wrench (spindle screw)

20 Mallet
30 Offset screwdriver (centripetal pump)
40 Ring spanner (centripetal pump lock ring)
100 Hexagon nut M 16 (centrifugal clutch)
200 Lubricating grease
310 Hex head screw M 16 x 300 (centrifugal clutch)
320 Hex head screw M 30 x 240 (centrifugal clutch)

340 Threaded pin M 16 x 50 (centrifugal clutch)
400 Clamp bolt, compl. (centrifugal clutch)
500 Disk (centrifugal clutch)
600 Compressing device, complete (disk stack compressing device)
610 Assembling device complete (sliding piston / closing chamber bottom
/ annular piston)
620 Mounting ring
630 Ring spanner (bowl lock ring)
640 Eye bolt, complete (bowl)
650 Assembling device, complete (closing chamber bottom / annular pis-
ton)
660 Double nipple (transporting the separator)

222 2063-9001-100 / 0509
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note

2063-9001-100 / 0509 223
5 Spare parts
5.1 Spare part requirements ...................................................................... 224

5.2 Guide to ordering spare parts .............................................................. 224

224 2063-9001-100 / 0509
5.1 Spare part requirements

Separator. The original spare parts are listed
in the spare parts catalog.
– safety risks,
– reduced availability of the separator and
Fig. 361 If a safety risk occurs when using non-original
ranty 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 40-0196-067
• 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.

2063-9001-100 / 0509 225
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note

226 2063-9001-100 / 0509
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Notater
Notes
Note

2063-9001-100 / 0509 227

Phone: +49 2522 77-0 · Fax: +49 2522 77-17 78
Parts Catalogue
Model: OSE 40-0196-067
Serial-No.: 9054-183
Bowl S/N: 9054-183
Order-No.: 943911795 / 012000
Mechanical Separation Technology

Werner-Habig-Strasse - D-59302 0elde
Tel.: +49 2522 77-0 - Fax: +49 2522 77-2488
Ws.production@geagroup.com - www.westfalia-separator.com
Spare parts order
This order-specific parts catalogue Only required when ordering spare parts for pump and pump connection
- forms the basis and is decisive for your spare parts order, parts:
- replaces the standard parts list in the manual supplied with the separator. - Model and number of pump see pump nameplate
Use of non-genuine spare parts

The information provided must be complete to avoid incorrect
The use of non-genuine spare parts leads to:
deliveries.
- safety risks,
- reduced durability of these parts,
- reduced availability of the separator and
- increased service requirement.
If a safety risk occurs when using non-original spare parts, this may
have legal consequences for the responsible persons.
In such cases, Westfalia Separator accepts no liability or warranty
claims.
Guide to ordering spare parts

A rapid and correct supply of spare parts can only be guaranteed if your
order includes the following details:
- Type see name-plate
- Serial-No. see name-plate
- Designation see order-specific parts catalogue
- Part Number see order-specific parts catalogue

- Bowl S/N: If it differs from the serial number of the ma-
chine,
the bowl serial number is engraved on the
bowl lock ring,
bowl bottom and bowl top.
GEA Westfalia Separator GmbH Date: 25.10.2010
PARTS CATALOG
ORDER-NO : 943911795 MACHINE SERIAL-NO : 9054-183 PLANT SERIAL-NO. :

Main Item 012000 BOWL SERIAL-NO : 9054-183 CONVEYOR SCREW SERIAL-NO:
TYPE : OSE 40-0196-067 CONTROL CABINET SIN :
MATERIAL-NO. : 9987-0258-553 Page: 3
Explanation
ET-Zeich.-Nr. = Spare part drawing no.
Aufl. in ET-Znr. = Breakdown in the spare part drawing. The respective assembly is shownin more detail in the stated spare part drawing.
POS = Pos. no. of the spare part drawing.
QTY. = Quantity related to the unit of quantity(ME), e.g. 1,00 for 1 piece or 1 set.
ME = Unit of quantity
ST = Piece
MM = Millimeter CM = Centimeter
DM = Decimeter M = Meter
GR = Gram KG = Kilogram
DM3 = Cubic decimeter M3 = Cubic meter
MM2 = Square millimeter CM2 = Square centimeter
DM2 = Square decimeter M2 = Square meter
ETS = Spare part code
1+2 = Part or assembly available.

3+4 = Part or assembly available to a limit extent. Contact manufakturer.
5 = Part or assembly also available as a set
6 = Variant part; stated in another place of the spare parts list.
7 = Part or assembly graphically shown; does not belong to the delivered version
9 = Part or assembly not available in this manufacturing stage.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 4
Contents
Part-No. Designation Page SparP Drwg N
2063-9000-100 BETRIEBSANLEITUNG 7
INSTRUCTION MANUAL
INSTRUCTION MANUAL
2063-1100-000 GESTELL VOLLST. 9 2063-4751-000
FRAME, COMPL.
2057-1031-000 BREMSBOLZEN VOLLST. 17 2057-4751-006
BRAKE BOLT, COMPL.
0008-4510-020 HALSLAGERBRUECKE VOLLST. 19 2057-4753-012
NECK BEARING BRIDGE, COMPL.
2063-3429-000 SPINDEL VOLLST. 21 2063-4753-000
SPINDLE, COMPL.
2063-3050-000 SATZ ANTRIEBSTEILE 23 2063-4753-001
SET OF DRIVE PARTS
2057-3385-110 FLIEHKRAFTKUPPLUNG VOLLST. 25 2057-4753-007
CENTRIFUGAL CLUTCH, COMPL.
0018-7614-000 MAGNETVENTILBLOCK VOLLST. 27 2057-4751-009
SOLENOID VALVE ASSEMBLY, COMPL.
2057-1015-000 FUSS VOLLST. 30 2057-4751-013
FOOT, COMPL.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 5
Contents
2063-9901-000 SATZ WERKZEUGE U.ZUBEHOERTEILE 32 2063-4759-000
SET OF TOOLS AND ACCESSORIES
2062-9820-000 PRESSVORRICHTUNG VOLLST. 36 2062-4759-000
COMPRESSING DEVICE, COMPL.
5889-7835-139 DREHSTROMMOTOR 38
THREE-PHASE AC MOTOR
2057-9928-030 SATZ BORDVERSCHRAUBUNGEN 39
SET OF SHIPBOARD SCREW COUPLINGS
2063-8800-000 HAUBE VOLLST. 40 2062-4758-000
HOOD, COMPL.
0026-2101-000 HALTERING VOLLST. 44 2058-4758-002
HOLDING RING, COMPL.
2062-8828-010 SENSORBLOCK VOLLST. 46 2061-4758-002
SENSOR BLOCK COMPL.
2063-2213-000 GREIFER VOLLST. 49 2062-4752-000
CENTRIPETAL PUMP, COMPL.
2063-6600-510 TROMMEL VOLLST. 51 2062-4756-000
BOWL, COMPL.
0024-0070-000 SCHILD 56
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 6
Contents
0024-3531-010 KLEBESCHILD 57
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 7
SparP Drwg N Pos Part-No. Designation Qty. ME ETS Expl.in spares drwg.
no.
2063-9000-100 BETRIEBSANLEITUNG 1,000 PC 2
INSTRUCTION MANUAL
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 8
no.
INSTRUCTION MANUAL
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 9
no.
2063-4751-000 2063-1100-000 GESTELL VOLLST. 1,000 PC 1
FRAME, COMPL.
0010 2057-1001-000 GESTELLUNTERTEIL 1,000 PC 2
LOWER SECTION OF FRAME
0020 2063-1002-010 GESTELLOBERTEIL 1,000 PC 2
UPPER SECTION OF FRAME
0030 0019-7038-400 SECHSKANTSCHRAUBE 8,000 PC 2
HEX HEAD SCREW
HEX HEAD SCREW
0070 0019-8910-030 VERSCHLUSSSCHRAUBE 2,000 PC 2
SCREW PLUG
0080 0007-1796-550 DICHTRING 2,000 PC 2
GASKET
0090 0001-1457-800 SCHAUGLAS 3,000 PC 2
SIGHT GLASS
0100 2057-1038-000 BREMSGEHAEUSE 1,000 PC 2
BRAKE HOUSING
0110 0006-4354-160 ZYLINDRISCHE DRUCKFEDER 1,000 PC 2
CYLINDRICAL PRESSURE SPRING
0120 2057-1031-000 BREMSBOLZEN VOLLST. 1,000 PC 1 2057-4751-006
BRAKE BOLT, COMPL.
0130 0021-3525-000 KEGELGRIFF 1,000 PC 2
TAPERED HANDLE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 10
no.
HEX HEAD SCREW
0150 0008-4510-020 HALSLAGERBRUECKE VOLLST. 1,000 PC 1 2057-4753-012
0160 0007-2643-750 DICHTRING 2,000 PC 2
GASKET
0180 0011-8070-000 GELENKLAGER 1,000 PC 2
SPHERICAL PLAIN BEARING
0190 0007-1958-750 DICHTRING 1,000 PC 2
GASKET
0200 2057-3131-000 LAGERGEHAEUSE 1,000 PC 2
BEARING HOUSING
0210 0026-5741-300 SCHEIBE 16,000 PC 2
WASHER / DISK
HEX HEAD SCREW
0230 0026-1328-300 FEDERRING 7,000 PC 2
LOCK WASHER
0240 2063-3429-000 SPINDEL VOLLST. 1,000 PC 1 2063-4753-000
SPINDLE, COMPL.
HEX HEAD SCREW
0270 2063-3050-000 SATZ ANTRIEBSTEILE 1,000 PC 1 2063-4753-001
SET OF DRIVE PARTS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 11
no.
0290 2062-1089-000 RING 1,000 PC 2
RING
0300 0007-2035-750 DICHTRING 1,000 PC 2
SKET
0310 2062-1066-000 SCHUTZKAPPE 1,000 PC 2
PROTECTIVE CAP
HEX HEAD SCREW
0330 2063-1464-000 ROHRSTUECK 1,000 PC 2
TUBE PIECE
0340 0018-3469-030 VERSCHRAUBUNG 1,000 PC 2
SCREW COUPLING
0350 0018-3215-030 STUTZEN 1,000 PC 2
CONNECTOR
0360 0018-7944-000 NIEDERDRUCKSCHLAUCH VOLLST. 1,000 PC 2
LOW PRESSURE HOSE, COMPL.
0370 2062-3266-000 SPINDELKAPPE 1,000 PC 2
SPINDLE CAP
0380 0007-2929-750 DICHTRING 1,000 PC 2
GASKET
0390 0018-7614-000 MAGNETVENTILBLOCK VOLLST. 1,000 PC 1 2057-4751-009
0400 0018-6585-710 SCHLAUCH 1,000 PC 2
HOSE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 12
no.
0410 0018-3812-300 SCHLAUCHSCHELLE 2,000 PC 2
HOSE CLIP
0420 0018-6490-710 SCHLAUCH 1,000 PC 2
HOSE
HOSE CLIP
0470 0018-6620-030 STUTZEN 1,000 PC 2
CONNECTOR
0490 0018-0994-260 STOPFEN 1,000 PC 2
PLUG
HEX HEAD SCREW
0510 0013-0312-300 SECHSKANTMUTTER 1,000 PC 2
HEXAGON NUT
0540 2057-1015-000 FUSS VOLLST. 4,000 PC 1 2057-4751-013
FOOT, COMPL.
0550 0026-1371-400 SCHEIBE 3,000 PC 2
WASHER / DISK
HEX HEAD SCREW
0570 0007-2638-750 DICHTRING 1,000 PC 2
GASKET
0580 0019-5384-050 RINGSCHRAUBE 2,000 PC 2
EYE SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 13
no.
0600 0019-1442-900 GEWINDESTOPFEN 1,000 PC 2
THREADED PLUG
0610 0005-1601-700 KABELDURCHFUEHRUNGSTUELLE 1,000 PC 2
CABLE SLEEVE
0620 2062-1145-000 HALTER 1,000 PC 2
HOLDER
0630 0005-0868-000 NAEHERUNGSINITIATOR 1,000 PC 2
PROXIMITY SENSOR
SCREW COUPLING
0650 0005-1720-900 SOCKEL 2,000 PC 2
BASE
0660 0019-2247-300 ZYLINDERSCHRAUBE 2,000 PC 2
ALLEN SCREW
0670 0005-1455-900 KABELBINDER 4,000 PC 2
CABLE TIE
ALLEN SCREW
0690 0024-4310-010 SATZ SCHILDER 1,000 PC 1
SET OF PLATES
0024-6324-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6327-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 14
no.
0024-6326-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6426-000 SCHILD 1,000 PC 2
PLATE
0024-6071-000 ABZIEHBILD "PFEIL" 1,000 PC 2
DECAL "ARROW"
0024-6330-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6329-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6328-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6325-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-3500-010 TYPENSCHILD 1,000 PC 2
TYPE PLATE
0000-0006-162 ENTFAELLT 1,000 PC 7
NOT APPLICABLEAPPLICABLE
0026-1571-300 KERBNAGEL 4,000 PC 2
NOTCHED NAIL
0024-6580-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-5380-000 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 15
no.
1000 2063-9901-000 SATZ WERKZEUGE U.ZUBEHOERTEILE 1,000 PC 1 2063-4759-000
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 17
no.
2057-4751-006 2057-1031-000 BREMSBOLZEN VOLLST. 1,000 PC 1
BRAKE BOLT, COMPL.
0010 2057-1039-000 BREMSBOLZEN 1,000 PC 2
BRAKE BOLT
0020 0021-3301-980 BREMSBELAG 1,000 PC 2
BRAKE LINING
0030 0019-2111-400 SENKSCHRAUBE 1,000 PC 2
COUNTERSUNK SCREW
0040 0019-6310-300 GEWINDESTIFT 1,000 PC 2
THREADED PIN
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 19
no.
2057-4753-012 0008-4510-020 HALSLAGERBRUECKE VOLLST. 1,000 PC 1
0010 0008-4506-020 HALSLAGERBRUECKE 1,000 PC 2
NECK BEARING BRIDGE
0020 0008-5007-150 HALSLAGERDRUCKRING 1,000 PC 2
NECK BEARING PRESSURE RING
THREADED PLUG
0040 0006-4377-060 SATZ HALSLAGERFEDERN 1,000 PC 2
SET OF NECK BEARING SPRINGS
0050 0026-1289-110 FEDERKOLBEN 6,000 PC 2
SPRING PISTON
0110 0024-6210-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 21
no.
2063-4753-000 2063-3429-000 SPINDEL VOLLST. 1,000 PC 1
SPINDLE, COMPL.
0010 2063-3410-000 SPINDEL 1,000 PC 2
SPINDLE
0020 0008-5002-000 HALSLAGERSCHUTZKAPPE 1,000 PC 2
NECK BEARING PROTECTION CAP
0030 0008-5009-050 ABSTANDSRING 1,000 PC 2
SPACING RING
0040 0011-0210-670 ZYLINDERROLLENLAGER 1,000 PC 2
CYLINDRICAL ROLLER BEARING
0050 0026-2499-000 STELLRING 1,000 PC 2
SET COLLAR
0060 0019-8964-400 GEWINDESTIFT 4,000 PC 2
THREADED PIN
0070 0008-2508-000 KUGELLAGERSCHLUSSRING 1,000 PC 2
BALL BEARING PROTECTION RING
0080 0011-7305-100 SCHRAEGKUGELLAGER 2,000 PC 2
ANGULAR CONTACT BALL BEARING
0090 0010-6205-010 LAGERHUELSE VOLLST. 1,000 PC 1
BEARING SLEEVE, COMPL.
0026-1101-030 ZYLINDERSTIFT 1,000 PC 2
CYLINDRICAL PIN
0100 0026-0314-170 SPANNSTIFT 1,000 PC 2
SPRING DOWEL SLEEVE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 23
no.
2063-4753-001 2063-3050-000 SATZ ANTRIEBSTEILE 1,000 PC 1
SET OF DRIVE PARTS
0010 2057-3385-110 FLIEHKRAFTKUPPLUNG VOLLST. 1,000 PC 1 2057-4753-007
0020 0026-1353-030 SCHEIBE 1,000 PC 2
WASHER / DISK
HEX HEAD SCREW
0040 0021-3312-900 ANTRIEBSRIEMEN 1,000 PC 2
DRIVE BELT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 25
no.
2057-4753-007 2057-3385-110 FLIEHKRAFTKUPPLUNG VOLLST. 1,000 PC 1
0010 2057-3365-010 KUPPLUNGSSCHEIBE 1,000 PC 2
CLUTCH PULLEY
0020 0011-6012-680 RILLENKUGELLAGER 3,000 PC 2
GROOVED BALL BEARING
0030 2057-3356-020 DISTANZHUELSE 1,000 PC 2
SPACER SLEEVE
0040 0026-0851-170 SICHERUNGSRING 2,000 PC 2
SECURING RING
0050 2057-3483-020 MITNEHMERSCHEIBE MHPA 1,000 PC 2
DRIVER, BALANCED WITH HALF KEY
SECURING RING
0070 2057-3474-000 FLACHRIEMENSCHEIBE 1,000 PC 2
FLAT-BELT PULLEY
ALLEN SCREW
0090 0021-3293-870 KUPPLUNGSKLOTZ 12,000 PC 2
CLUTCH SHOE
0100 2057-3367-000 SCHEIBE 1,000 PC 2
WASHER / DISK
SECURING RING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 27
no.
2057-4751-009 0018-7614-000 MAGNETVENTILBLOCK VOLLST. 1,000 PC 1
0010 0018-7614-920 DRUCKREGLER 1,000 PC 2
PRESSURE REGULATOR
0020 0018-1763-630 MUFFENKUGELHAHN 1,000 PC 1
BALL VALVE
0018-1763-280 GRIFF 1,000 PC 2
HANDLE
0030 0001-1572-600 DRUCKMESSGERAET 1,000 PC 2
PRESSURE GAUGE
0040 0018-7614-900 FILTEREINSATZ 1,000 PC 2
FILTER INSERT
0070 0018-6654-010 MAGNETSPULE 2,000 PC 2
SOLENOID
0080 0018-6654-040 GEHAEUSE 2,000 PC 2
HOUSING
0090 0018-5947-820 MEMBRANE 2,000 PC 2
DIAPHRAGM
0100 0018-7614-930 MAGNETKERN 2,000 PC 2
SOLENOID CORE
0110 0018-5118-040 GERAETESTECKDOSE 2,000 PC 2
COUPLER SOCKET
0130 0018-7614-910 SCHLAUCH 1,000 PC 2
HOSE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 28
no.
0140 0018-6654-030 SATZ DICHTUNGEN 1,000 PC 2
SET OF SEALS
ALLEN SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 30
no.
2057-4751-013 2057-1015-000 FUSS VOLLST. 4,000 PC 1
FOOT, COMPL.
0010 2057-1467-000 PLATTE 1,000 PC 2
PLATE
0020 0021-3309-750 MASCHINENFUSS 1,000 PC 2
MACHINE FOOT
HEX HEAD SCREW
HEX HEAD SCREW
0050 0026-1335-300 SCHEIBE 1,000 PC 2
WASHER / DISK
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 32
no.
2063-4759-000 2063-9901-000 SATZ WERKZEUGE U.ZUBEHOERTEILE 1,000 PC 1
0010 0003-0596-320 STECKSCHLUESSEL VOLLST. 1,000 PC 1
SOCKET WRENCH, COMPL.
0026-1438-170 SPRENGRING 1,000 PC 2
SNAP RING
0020 0003-0644-300 SCHLAGBOLZEN 1,000 PC 2
MALLET
0030 0003-3797-320 WINKELSCHRAUBENDREHER 1,000 PC 2
OFFSET SCREWDRIVER
0040 0003-3998-000 RINGSCHLUESSEL 1,000 PC 2
ANNULAR WRENCH
HEXAGON NUT
0200 0015-0082-000 SCHMIERFETT 1,000 PC 2
LUBRICATING GREASE
HEX HEAD SCREW
HEX HEAD SCREW
0340 0019-6351-150 GEWINDESTIFT 1,000 PC 2
THREADED PIN
0400 2057-9828-010 SPANNBOLZEN VOLLST. 1,000 PC 1
CLAMP BOLT, COMPL.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 33
no.
0019-6991-150 SECHSKANTSCHRAUBE 1,000 PC 2
HEX HEAD SCREW
0026-1371-300 SCHEIBE 1,000 PC 2
WASHER / DISK
0013-0280-300 SECHSKANTMUTTER 1,000 PC 2
HEXAGON NUT
0500 2058-9939-000 SCHEIBE 1,000 PC 2
WASHER / DISK
0600 2062-9820-000 PRESSVORRICHTUNG VOLLST. 1,000 PC 1 2062-4759-000
0610 2063-9860-000 MONTAGEVORRICHTUNG VOLLST. 1,000 PC 1
MOUNTING TOOL, COMPL.
2062-9939-000 SCHEIBE 3,000 PC 2
WASHER / DISK
0019-6140-150 ZYLINDERSCHRAUBE 3,000 PC 2
ALLEN SCREW
0620 2063-9823-000 MONTAGERING 1,000 PC 2
MOUNTING RING
0630 2063-9943-000 RINGSCHLUESSEL VOLLST. 1,000 PC 1
ANNULAR WRENCH, COMPL.
HEX HEAD SCREW
HEXAGON NUT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 34
no.
0640 2062-9982-000 RINGSCHRAUBE VOLLST. 1,000 PC 1 2062-4759-004
EYE BOLT, COMPL.
2062-9877-010 BOLZEN 1,000 PC 2
BOLT
0013-0393-030 RINGMUTTER 1,000 PC 2
RING NUT
HEXAGON NUT
0024-3579-020 SCHILD 1,000 PC 2
PLATE
HEX HEAD SCREW
0013-2565-260 FLUEGELMUTTER 1,000 PC 2
WING NUT
0018-4250-030 ROHR 1,000 PC 2
PIPE
HEXAGON NUT
0660 0018-2916-050 DOPPELNIPPEL 1,000 PC 2
DOUBLE NIPPLE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 36
no.
2062-4759-000 2062-9820-000 PRESSVORRICHTUNG VOLLST. 1,000 PC 1
0010 2062-9877-000 BOLZEN 1,000 PC 2
BOLT
0020 2062-9918-000 HEBEL 1,000 PC 2
LEVER
0030 0013-0393-030 RINGMUTTER 1,000 PC 2
RING NUT
0040 2062-9822-000 GLOCKE 1,000 PC 2
BELL-SHAPED PIECE
0050 2062-9939-010 SCHEIBE 1,000 PC 2
WASHER / DISK
0060 0024-3579-020 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 38
no.
5889-7835-139 DREHSTROMMOTOR 1,000 PC 2
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 39
no.
2057-9928-030 SATZ BORDVERSCHRAUBUNGEN 1,000 PC 1
SCREW COUPLING
SCREW COUPLING
SCREW COUPLING
0040 0005-4476-630 REDUKTION 1,000 PC 2
REDUCTION
0050 0005-4471-630 REDUKTION 1,000 PC 2
REDUCTION
SCREW COUPLING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 40
no.
2062-4758-000 2063-8800-000 HAUBE VOLLST. 1,000 PC 1
HOOD, COMPL.
0010 2063-8808-000 HAUBE 1,000 PC 2
HOOD
0020 0026-2101-000 HALTERING VOLLST. 1,000 PC 1 2058-4758-002
0050 2062-8828-010 SENSORBLOCK VOLLST. 1,000 PC 1 2061-4758-002
SENSOR BLOCK COMPL.
0080 0018-5956-030 STUTZEN 3,000 PC 2
CONNECTOR
0090 2062-8829-000 SATZ BLENDEN 1,000 PC 1
SET OF ORIFICE PLATES
2062-8473-000 BLENDE 2,000 PC 2
LENS COVER
2062-8473-010 BLENDE 2,000 PC 2
LENS COVER
2062-8473-020 BLENDE 2,000 PC 2
LENS COVER
2062-8473-030 BLENDE 2,000 PC 2
LENS COVER
2062-8473-040 BLENDE 2,000 PC 2
LENS COVER
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 41
no.
2062-8473-050 BLENDE 2,000 PC 2
LENS COVER
0100 0018-7028-100 WELLROHRSCHLAUCH VOLLST. 2,000 PC 1
CORRUGATED TUBE, COMPL.
0007-1943-630 DICHTRING 2,000 PC 2
GASKET
0110 0018-6615-000 STUTZEN 1,000 PC 2
CONNECTOR
0120 0019-1611-300 FLACHKOPFSCHRAUBE 2,000 PC 2
PAN HEAD SCREW
0130 2042-2191-000 GRIFFKOERPER GESCHW. 1,000 PC 2
HANDLE CONNECTION PIECE, WELDED
0140 0007-1944-750 DICHTRING 2,000 PC 2
GASKET
0150 2058-8839-000 RUECKSCHLAGVENTIL 1,000 PC 2
NON-RETURN VALVE
0160 0013-1006-600 UEBERWURFMUTTER 1,000 PC 2
COUPLING NUT
PRESSURE GAUGE
SCREW PLUG
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 42
no.
NON-RETURN VALVE
0210 0018-1593-000 ROHRSTUECK 1,000 PC 2
LENGTH OF PIPE
0220 0005-1742-808 SCHUTZSCHLAUCH 0,500 M 2
PROTECTIVE HOSE
0230 0005-1827-280 KLEMMENKASTEN 1,000 PC 2
TERMINAL BOX
ALLEN SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 44
no.
2058-4758-002 0026-2101-000 HALTERING VOLLST. 1,000 PC 1
0010 2058-7788-000 BUEGEL 1,000 PC 2
STIRRUP
HEX HEAD SCREW
HEXAGON NUT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 46
no.
2061-4758-002 2062-8828-010 SENSORBLOCK VOLLST. 1,000 PC 1
SENSOR BLOCK COMPL.
0010 0018-8133-600 MAGNETVENTIL 2,000 PC 1
SOLENOID VALVE
0018-5545-830 MEMBRANE 1,000 PC 2
DIAPHRAGM
0007-2987-830 DICHTRING 3,000 PC 2
GASKET
0020 0005-1529-300 DRUCKTRANSMITTER 2,000 PC 2
PRESSURE TRANSMITTER
0030 0005-1464-060 WASSERDETEKTOR 1,000 PC 1
WATER DETECTOR
0007-1941-630 DICHTRING 1,000 PC 2
GASKET
0040 0007-2501-830 DICHTRING 3,000 PC 2
GASKET
0050 2062-8828-910 ABSPERRVENTIL 2,000 PC 2
SHUT-OFF VALVE
ALLEN SCREW
0070 0026-1345-300 SCHEIBE 3,000 PC 2
WASHER / DISK
0080 2062-8828-920 SATZ ERSATZTEILE 1,000 PC 2
SET OF SPARE PARTS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 47
no.
SET OF SEALS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 49
no.
2062-4752-000 2063-2213-000 GREIFER VOLLST. 1,000 PC 1
0010 2063-2241-000 GREIFER VOLLST. 1,000 PC 2
0020 0007-1944-750 DICHTRING 1,000 PC 2
GASKET
0030 2062-2337-020 STEUERGREIFER 1,000 PC 2
SENSING LIQUID PUMP
0040 0007-3285-750 DICHTRING 1,000 PC 2
GASKET
0050 0007-2925-750 DICHTRING 1,000 PC 2
GASKET
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 51
no.
2062-4756-000 2063-6600-510 TROMMEL VOLLST. 1,000 PC 1
BOWL, COMPL.
0005 2063-6600-518 TROMMEL VOLLST.(VORGEWUCHTET) 1,000 PC 9
BOWL COMPL. (PRE-BALANCED)
0020 2063-6604-000 TROMMELUNTERTEIL VOLLST. 1,000 PC 4
BOWL BOTTOM, COMPL.
0030 0007-3796-760 DICHTRING 1,000 PC 2
GASKET
0040 0004-3273-810 KOLBENFUEHRUNGSRING 1,000 PC 2
PISTON GUIDE RING
0050 2063-6698-000 WASSERKAMMERBODEN 1,000 PC 2
WATER CHAMBER BOTTOM
0070 0007-3169-750 DICHTRING 2,000 PC 2
GASKET
ALLEN SCREW
0090 2063-6503-000 RINGKOLBEN 1,000 PC 2
ANNULAR PISTON
0100 0007-3799-840 DICHTRING 1,000 PC 2
GASKET
0110 0007-3457-790 DICHTRING 1,000 PC 2
GASKET
0120 2063-6426-000 SCHLIESSKAMMERBODEN 1,000 PC 2
CLOSING CHAMBER BOTTOM
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 52
no.
0130 0007-2827-790 DICHTRING 1,000 PC 2
GASKET
0140 0007-3216-760 DICHTRING 2,000 PC 2
GASKET
0160 0004-1595-810 FUEHRUNGSBAND 1,000 PC 2
GASKET
ALLEN SCREW
0180 2063-6501-000 KOLBENSCHIEBER 1,000 PC 2
SLIDING PISTON
0190 0007-3798-760 DICHTRING 1,000 PC 2
GASKET
GASKET
0210 2063-6621-000 VERTEILER 1,000 PC 4
DISTRIBUTOR
0220 2063-6660-500 TELLEREINSATZ VOLLST. 1,000 PC 3
DISC STACK, COMPL.
2063-6663-000 TELLER VOLLST. 135,000 PC 2
DISC, COMPL.
2063-6666-000 ABSCHLUSSTELLER 1,000 PC 2
BLIND DISC
0230 2063-6652-000 SCHEIDETELLER 1,000 PC 2
SEPARATING DISC
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 53
no.
0240 2063-6610-000 TROMMELDECKEL VOLLST. 1,000 PC 3
BOWL TOP, COMPL.
CYLINDRICAL PIN
0250 0007-3800-910 DICHTRING 1,000 PC 2
GASKET
0260 0007-2625-830 DICHTRING 1,000 PC 2
GASKET
0270 0007-2080-750 DICHTRING 1,000 PC 2
GASKET
0280 2063-6631-000 VERSCHLUSSRING 1,000 PC 4
LOCK RING
0290 0019-6335-400 GEWINDESTIFT 2,000 PC 2
THREADED PIN
0300 0007-2940-750 DICHTRING 1,000 PC 2
GASKET
0310 0007-2023-750 DICHTRING 2,000 PC 2
GASKET
0320 2178-6645-040 GREIFERKAMMERDECKEL 1,000 PC 2
CENTRIPETAL PUMP CHAMBER COVER
LOCK RING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 54
no.
0350 0019-0966-360 SPINDELSCHRAUBE 1,000 PC 2
SPINDLE SCREW
0360 0007-1941-750 DICHTRING 1,000 PC 2
GASKET
0990 0024-6180-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 56
no.
0024-0070-000 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-553 Page: 57
no.
0024-3531-010 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
Parts Catalogue
Model: OSE 40-0196-067
Bowl S/N: 9054-184
Order-No.: 943911795 / 022000

Tel.: +49 2522 77-0 - Fax: +49 2522 77-2488
Spare parts order

deliveries.
- safety risks,
claims.


chine,
bowl lock ring,
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 3
Explanation
ST = Piece

PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 4
Contents
INSTRUCTION MANUAL
INSTRUCTION MANUAL
2063-1100-000 GESTELL VOLLST. 9 2063-4751-000
FRAME, COMPL.
BRAKE BOLT, COMPL.
2063-3429-000 SPINDEL VOLLST. 21 2063-4753-000
SPINDLE, COMPL.
SET OF DRIVE PARTS
2057-1015-000 FUSS VOLLST. 30 2057-4751-013
FOOT, COMPL.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 5
Contents
2063-8800-000 HAUBE VOLLST. 40 2062-4758-000
HOOD, COMPL.
SENSOR BLOCK COMPL.
2063-2213-000 GREIFER VOLLST. 49 2062-4752-000
2063-6600-510 TROMMEL VOLLST. 51 2062-4756-000
BOWL, COMPL.
0024-0070-000 SCHILD 56
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 6
Contents
0024-3531-010 KLEBESCHILD 57
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 7
no.
INSTRUCTION MANUAL
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 8
no.
INSTRUCTION MANUAL
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 9
no.
FRAME, COMPL.
HEX HEAD SCREW
HEX HEAD SCREW
SCREW PLUG
0080 0007-1796-550 DICHTRING 2,000 PC 2
GASKET
0090 0001-1457-800 SCHAUGLAS 3,000 PC 2
SIGHT GLASS
BRAKE HOUSING
BRAKE BOLT, COMPL.
0130 0021-3525-000 KEGELGRIFF 1,000 PC 2
TAPERED HANDLE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 10
no.
HEX HEAD SCREW
0160 0007-2643-750 DICHTRING 2,000 PC 2
GASKET
0180 0011-8070-000 GELENKLAGER 1,000 PC 2
0190 0007-1958-750 DICHTRING 1,000 PC 2
GASKET
BEARING HOUSING
0210 0026-5741-300 SCHEIBE 16,000 PC 2
WASHER / DISK
HEX HEAD SCREW
0230 0026-1328-300 FEDERRING 7,000 PC 2
LOCK WASHER
SPINDLE, COMPL.
HEX HEAD SCREW
SET OF DRIVE PARTS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 11
no.
0290 2062-1089-000 RING 1,000 PC 2
RING
0300 0007-2035-750 DICHTRING 1,000 PC 2
SKET
0310 2062-1066-000 SCHUTZKAPPE 1,000 PC 2
PROTECTIVE CAP
HEX HEAD SCREW
0330 2063-1464-000 ROHRSTUECK 1,000 PC 2
TUBE PIECE
SCREW COUPLING
0350 0018-3215-030 STUTZEN 1,000 PC 2
CONNECTOR
0370 2062-3266-000 SPINDELKAPPE 1,000 PC 2
SPINDLE CAP
0380 0007-2929-750 DICHTRING 1,000 PC 2
GASKET
0400 0018-6585-710 SCHLAUCH 1,000 PC 2
HOSE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 12
no.
HOSE CLIP
0420 0018-6490-710 SCHLAUCH 1,000 PC 2
HOSE
HOSE CLIP
0470 0018-6620-030 STUTZEN 1,000 PC 2
CONNECTOR
0490 0018-0994-260 STOPFEN 1,000 PC 2
PLUG
HEX HEAD SCREW
HEXAGON NUT
0540 2057-1015-000 FUSS VOLLST. 4,000 PC 1 2057-4751-013
FOOT, COMPL.
0550 0026-1371-400 SCHEIBE 3,000 PC 2
WASHER / DISK
HEX HEAD SCREW
0570 0007-2638-750 DICHTRING 1,000 PC 2
GASKET
0580 0019-5384-050 RINGSCHRAUBE 2,000 PC 2
EYE SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 13
no.
THREADED PLUG
CABLE SLEEVE
0620 2062-1145-000 HALTER 1,000 PC 2
HOLDER
PROXIMITY SENSOR
SCREW COUPLING
0650 0005-1720-900 SOCKEL 2,000 PC 2
BASE
ALLEN SCREW
0670 0005-1455-900 KABELBINDER 4,000 PC 2
CABLE TIE
ALLEN SCREW
0690 0024-4310-010 SATZ SCHILDER 1,000 PC 1
SET OF PLATES
0024-6324-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6327-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 14
no.
0024-6326-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6426-000 SCHILD 1,000 PC 2
PLATE
DECAL "ARROW"
0024-6330-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6329-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6328-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6325-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-3500-010 TYPENSCHILD 1,000 PC 2
TYPE PLATE
0000-0006-162 ENTFAELLT 1,000 PC 7
0026-1571-300 KERBNAGEL 4,000 PC 2
NOTCHED NAIL
0024-6580-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-5380-000 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 15
no.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 17
no.
BRAKE BOLT, COMPL.
0010 2057-1039-000 BREMSBOLZEN 1,000 PC 2
BRAKE BOLT
0020 0021-3301-980 BREMSBELAG 1,000 PC 2
BRAKE LINING
0030 0019-2111-400 SENKSCHRAUBE 1,000 PC 2
COUNTERSUNK SCREW
0040 0019-6310-300 GEWINDESTIFT 1,000 PC 2
THREADED PIN
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 19
no.
NECK BEARING BRIDGE
THREADED PLUG
0050 0026-1289-110 FEDERKOLBEN 6,000 PC 2
SPRING PISTON
0110 0024-6210-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 21
no.
SPINDLE, COMPL.
0010 2063-3410-000 SPINDEL 1,000 PC 2
SPINDLE
0030 0008-5009-050 ABSTANDSRING 1,000 PC 2
SPACING RING
0050 0026-2499-000 STELLRING 1,000 PC 2
SET COLLAR
0060 0019-8964-400 GEWINDESTIFT 4,000 PC 2
THREADED PIN
CYLINDRICAL PIN
0100 0026-0314-170 SPANNSTIFT 1,000 PC 2
SPRING DOWEL SLEEVE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 23
no.
SET OF DRIVE PARTS
0020 0026-1353-030 SCHEIBE 1,000 PC 2
WASHER / DISK
HEX HEAD SCREW
DRIVE BELT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 25
no.
CLUTCH PULLEY
SPACER SLEEVE
SECURING RING
SECURING RING
FLAT-BELT PULLEY
ALLEN SCREW
CLUTCH SHOE
0100 2057-3367-000 SCHEIBE 1,000 PC 2
WASHER / DISK
SECURING RING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 27
no.
0010 0018-7614-920 DRUCKREGLER 1,000 PC 2
PRESSURE REGULATOR
BALL VALVE
0018-1763-280 GRIFF 1,000 PC 2
HANDLE
PRESSURE GAUGE
FILTER INSERT
0070 0018-6654-010 MAGNETSPULE 2,000 PC 2
SOLENOID
0080 0018-6654-040 GEHAEUSE 2,000 PC 2
HOUSING
0090 0018-5947-820 MEMBRANE 2,000 PC 2
DIAPHRAGM
0100 0018-7614-930 MAGNETKERN 2,000 PC 2
SOLENOID CORE
COUPLER SOCKET
0130 0018-7614-910 SCHLAUCH 1,000 PC 2
HOSE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 28
no.
SET OF SEALS
ALLEN SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 30
no.
2057-4751-013 2057-1015-000 FUSS VOLLST. 4,000 PC 1
FOOT, COMPL.
0010 2057-1467-000 PLATTE 1,000 PC 2
PLATE
MACHINE FOOT
HEX HEAD SCREW
HEX HEAD SCREW
0050 0026-1335-300 SCHEIBE 1,000 PC 2
WASHER / DISK
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 32
no.
0026-1438-170 SPRENGRING 1,000 PC 2
SNAP RING
0020 0003-0644-300 SCHLAGBOLZEN 1,000 PC 2
MALLET
OFFSET SCREWDRIVER
ANNULAR WRENCH
HEXAGON NUT
0200 0015-0082-000 SCHMIERFETT 1,000 PC 2
LUBRICATING GREASE
HEX HEAD SCREW
HEX HEAD SCREW
0340 0019-6351-150 GEWINDESTIFT 1,000 PC 2
THREADED PIN
CLAMP BOLT, COMPL.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 33
no.
HEX HEAD SCREW
0026-1371-300 SCHEIBE 1,000 PC 2
WASHER / DISK
HEXAGON NUT
0500 2058-9939-000 SCHEIBE 1,000 PC 2
WASHER / DISK
2062-9939-000 SCHEIBE 3,000 PC 2
WASHER / DISK
ALLEN SCREW
0620 2063-9823-000 MONTAGERING 1,000 PC 2
MOUNTING RING
HEX HEAD SCREW
HEXAGON NUT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 34
no.
EYE BOLT, COMPL.
2062-9877-010 BOLZEN 1,000 PC 2
BOLT
0013-0393-030 RINGMUTTER 1,000 PC 2
RING NUT
HEXAGON NUT
0024-3579-020 SCHILD 1,000 PC 2
PLATE
HEX HEAD SCREW
WING NUT
0018-4250-030 ROHR 1,000 PC 2
PIPE
HEXAGON NUT
0660 0018-2916-050 DOPPELNIPPEL 1,000 PC 2
DOUBLE NIPPLE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 36
no.
0010 2062-9877-000 BOLZEN 1,000 PC 2
BOLT
0020 2062-9918-000 HEBEL 1,000 PC 2
LEVER
0030 0013-0393-030 RINGMUTTER 1,000 PC 2
RING NUT
0040 2062-9822-000 GLOCKE 1,000 PC 2
BELL-SHAPED PIECE
0050 2062-9939-010 SCHEIBE 1,000 PC 2
WASHER / DISK
0060 0024-3579-020 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 38
no.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 39
no.
SCREW COUPLING
SCREW COUPLING
SCREW COUPLING
0040 0005-4476-630 REDUKTION 1,000 PC 2
REDUCTION
0050 0005-4471-630 REDUKTION 1,000 PC 2
REDUCTION
SCREW COUPLING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 40
no.
2062-4758-000 2063-8800-000 HAUBE VOLLST. 1,000 PC 1
HOOD, COMPL.
0010 2063-8808-000 HAUBE 1,000 PC 2
HOOD
SENSOR BLOCK COMPL.
0080 0018-5956-030 STUTZEN 3,000 PC 2
CONNECTOR
0090 2062-8829-000 SATZ BLENDEN 1,000 PC 1
2062-8473-000 BLENDE 2,000 PC 2
LENS COVER
2062-8473-010 BLENDE 2,000 PC 2
LENS COVER
2062-8473-020 BLENDE 2,000 PC 2
LENS COVER
2062-8473-030 BLENDE 2,000 PC 2
LENS COVER
2062-8473-040 BLENDE 2,000 PC 2
LENS COVER
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 41
no.
2062-8473-050 BLENDE 2,000 PC 2
LENS COVER
0007-1943-630 DICHTRING 2,000 PC 2
GASKET
0110 0018-6615-000 STUTZEN 1,000 PC 2
CONNECTOR
PAN HEAD SCREW
0140 0007-1944-750 DICHTRING 2,000 PC 2
GASKET
NON-RETURN VALVE
COUPLING NUT
PRESSURE GAUGE
SCREW PLUG
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 42
no.
NON-RETURN VALVE
0210 0018-1593-000 ROHRSTUECK 1,000 PC 2
LENGTH OF PIPE
PROTECTIVE HOSE
TERMINAL BOX
ALLEN SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 44
no.
0010 2058-7788-000 BUEGEL 1,000 PC 2
STIRRUP
HEX HEAD SCREW
HEXAGON NUT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 46
no.
SENSOR BLOCK COMPL.
0010 0018-8133-600 MAGNETVENTIL 2,000 PC 1
SOLENOID VALVE
0018-5545-830 MEMBRANE 1,000 PC 2
DIAPHRAGM
0007-2987-830 DICHTRING 3,000 PC 2
GASKET
WATER DETECTOR
0007-1941-630 DICHTRING 1,000 PC 2
GASKET
0040 0007-2501-830 DICHTRING 3,000 PC 2
GASKET
SHUT-OFF VALVE
ALLEN SCREW
0070 0026-1345-300 SCHEIBE 3,000 PC 2
WASHER / DISK
SET OF SPARE PARTS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 47
no.
SET OF SEALS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 49
no.
0020 0007-1944-750 DICHTRING 1,000 PC 2
GASKET
SENSING LIQUID PUMP
0040 0007-3285-750 DICHTRING 1,000 PC 2
GASKET
0050 0007-2925-750 DICHTRING 1,000 PC 2
GASKET
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 51
no.
BOWL, COMPL.
BOWL BOTTOM, COMPL.
0030 0007-3796-760 DICHTRING 1,000 PC 2
GASKET
PISTON GUIDE RING
0070 0007-3169-750 DICHTRING 2,000 PC 2
GASKET
ALLEN SCREW
0090 2063-6503-000 RINGKOLBEN 1,000 PC 2
ANNULAR PISTON
0100 0007-3799-840 DICHTRING 1,000 PC 2
GASKET
0110 0007-3457-790 DICHTRING 1,000 PC 2
GASKET
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 52
no.
0130 0007-2827-790 DICHTRING 1,000 PC 2
GASKET
0140 0007-3216-760 DICHTRING 2,000 PC 2
GASKET
GASKET
ALLEN SCREW
SLIDING PISTON
0190 0007-3798-760 DICHTRING 1,000 PC 2
GASKET
GASKET
0210 2063-6621-000 VERTEILER 1,000 PC 4
DISTRIBUTOR
DISC STACK, COMPL.
2063-6663-000 TELLER VOLLST. 135,000 PC 2
DISC, COMPL.
BLIND DISC
SEPARATING DISC
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 53
no.
BOWL TOP, COMPL.
CYLINDRICAL PIN
0250 0007-3800-910 DICHTRING 1,000 PC 2
GASKET
0260 0007-2625-830 DICHTRING 1,000 PC 2
GASKET
0270 0007-2080-750 DICHTRING 1,000 PC 2
GASKET
LOCK RING
0290 0019-6335-400 GEWINDESTIFT 2,000 PC 2
THREADED PIN
0300 0007-2940-750 DICHTRING 1,000 PC 2
GASKET
0310 0007-2023-750 DICHTRING 2,000 PC 2
GASKET
LOCK RING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 54
no.
SPINDLE SCREW
0360 0007-1941-750 DICHTRING 1,000 PC 2
GASKET
0990 0024-6180-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 56
no.
0024-0070-000 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-559 Page: 57
no.
0024-3531-010 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
Parts Catalogue
Model: OSE 40-0196-067
Bowl S/N: 9054-178
Order-No.: 943911795 / 032000

Tel.: +49 2522 77-0 - Fax: +49 2522 77-2488
Spare parts order

deliveries.
- safety risks,
claims.


chine,
bowl lock ring,
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 3
Explanation
ST = Piece

PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 4
Contents
INSTRUCTION MANUAL
INSTRUCTION MANUAL
2063-1100-000 GESTELL VOLLST. 9 2063-4751-000
FRAME, COMPL.
BRAKE BOLT, COMPL.
2063-3429-000 SPINDEL VOLLST. 21 2063-4753-000
SPINDLE, COMPL.
SET OF DRIVE PARTS
2057-1015-000 FUSS VOLLST. 30 2057-4751-013
FOOT, COMPL.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 5
Contents
2063-8800-000 HAUBE VOLLST. 40 2062-4758-000
HOOD, COMPL.
SENSOR BLOCK COMPL.
2063-2213-000 GREIFER VOLLST. 49 2062-4752-000
2063-6600-510 TROMMEL VOLLST. 51 2062-4756-000
BOWL, COMPL.
0024-0070-000 SCHILD 56
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 6
Contents
0024-3531-010 KLEBESCHILD 57
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 7
no.
INSTRUCTION MANUAL
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 8
no.
INSTRUCTION MANUAL
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 9
no.
FRAME, COMPL.
HEX HEAD SCREW
HEX HEAD SCREW
SCREW PLUG
0080 0007-1796-550 DICHTRING 2,000 PC 2
GASKET
0090 0001-1457-800 SCHAUGLAS 3,000 PC 2
SIGHT GLASS
BRAKE HOUSING
BRAKE BOLT, COMPL.
0130 0021-3525-000 KEGELGRIFF 1,000 PC 2
TAPERED HANDLE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 10
no.
HEX HEAD SCREW
0160 0007-2643-750 DICHTRING 2,000 PC 2
GASKET
0180 0011-8070-000 GELENKLAGER 1,000 PC 2
0190 0007-1958-750 DICHTRING 1,000 PC 2
GASKET
BEARING HOUSING
0210 0026-5741-300 SCHEIBE 16,000 PC 2
WASHER / DISK
HEX HEAD SCREW
0230 0026-1328-300 FEDERRING 7,000 PC 2
LOCK WASHER
SPINDLE, COMPL.
HEX HEAD SCREW
SET OF DRIVE PARTS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 11
no.
0290 2062-1089-000 RING 1,000 PC 2
RING
0300 0007-2035-750 DICHTRING 1,000 PC 2
SKET
0310 2062-1066-000 SCHUTZKAPPE 1,000 PC 2
PROTECTIVE CAP
HEX HEAD SCREW
0330 2063-1464-000 ROHRSTUECK 1,000 PC 2
TUBE PIECE
SCREW COUPLING
0350 0018-3215-030 STUTZEN 1,000 PC 2
CONNECTOR
0370 2062-3266-000 SPINDELKAPPE 1,000 PC 2
SPINDLE CAP
0380 0007-2929-750 DICHTRING 1,000 PC 2
GASKET
0400 0018-6585-710 SCHLAUCH 1,000 PC 2
HOSE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 12
no.
HOSE CLIP
0420 0018-6490-710 SCHLAUCH 1,000 PC 2
HOSE
HOSE CLIP
0470 0018-6620-030 STUTZEN 1,000 PC 2
CONNECTOR
0490 0018-0994-260 STOPFEN 1,000 PC 2
PLUG
HEX HEAD SCREW
HEXAGON NUT
0540 2057-1015-000 FUSS VOLLST. 4,000 PC 1 2057-4751-013
FOOT, COMPL.
0550 0026-1371-400 SCHEIBE 3,000 PC 2
WASHER / DISK
HEX HEAD SCREW
0570 0007-2638-750 DICHTRING 1,000 PC 2
GASKET
0580 0019-5384-050 RINGSCHRAUBE 2,000 PC 2
EYE SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 13
no.
THREADED PLUG
CABLE SLEEVE
0620 2062-1145-000 HALTER 1,000 PC 2
HOLDER
PROXIMITY SENSOR
SCREW COUPLING
0650 0005-1720-900 SOCKEL 2,000 PC 2
BASE
ALLEN SCREW
0670 0005-1455-900 KABELBINDER 4,000 PC 2
CABLE TIE
ALLEN SCREW
0690 0024-4310-010 SATZ SCHILDER 1,000 PC 1
SET OF PLATES
0024-6324-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6327-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 14
no.
0024-6326-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6426-000 SCHILD 1,000 PC 2
PLATE
DECAL "ARROW"
0024-6330-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6329-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6328-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6325-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-3500-010 TYPENSCHILD 1,000 PC 2
TYPE PLATE
0000-0006-162 ENTFAELLT 1,000 PC 7
0026-1571-300 KERBNAGEL 4,000 PC 2
NOTCHED NAIL
0024-6580-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-5380-000 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 15
no.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 17
no.
BRAKE BOLT, COMPL.
0010 2057-1039-000 BREMSBOLZEN 1,000 PC 2
BRAKE BOLT
0020 0021-3301-980 BREMSBELAG 1,000 PC 2
BRAKE LINING
0030 0019-2111-400 SENKSCHRAUBE 1,000 PC 2
COUNTERSUNK SCREW
0040 0019-6310-300 GEWINDESTIFT 1,000 PC 2
THREADED PIN
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 19
no.
NECK BEARING BRIDGE
THREADED PLUG
0050 0026-1289-110 FEDERKOLBEN 6,000 PC 2
SPRING PISTON
0110 0024-6210-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 21
no.
SPINDLE, COMPL.
0010 2063-3410-000 SPINDEL 1,000 PC 2
SPINDLE
0030 0008-5009-050 ABSTANDSRING 1,000 PC 2
SPACING RING
0050 0026-2499-000 STELLRING 1,000 PC 2
SET COLLAR
0060 0019-8964-400 GEWINDESTIFT 4,000 PC 2
THREADED PIN
CYLINDRICAL PIN
0100 0026-0314-170 SPANNSTIFT 1,000 PC 2
SPRING DOWEL SLEEVE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 23
no.
SET OF DRIVE PARTS
0020 0026-1353-030 SCHEIBE 1,000 PC 2
WASHER / DISK
HEX HEAD SCREW
DRIVE BELT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 25
no.
CLUTCH PULLEY
SPACER SLEEVE
SECURING RING
SECURING RING
FLAT-BELT PULLEY
ALLEN SCREW
CLUTCH SHOE
0100 2057-3367-000 SCHEIBE 1,000 PC 2
WASHER / DISK
SECURING RING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 27
no.
0010 0018-7614-920 DRUCKREGLER 1,000 PC 2
PRESSURE REGULATOR
BALL VALVE
0018-1763-280 GRIFF 1,000 PC 2
HANDLE
PRESSURE GAUGE
FILTER INSERT
0070 0018-6654-010 MAGNETSPULE 2,000 PC 2
SOLENOID
0080 0018-6654-040 GEHAEUSE 2,000 PC 2
HOUSING
0090 0018-5947-820 MEMBRANE 2,000 PC 2
DIAPHRAGM
0100 0018-7614-930 MAGNETKERN 2,000 PC 2
SOLENOID CORE
COUPLER SOCKET
0130 0018-7614-910 SCHLAUCH 1,000 PC 2
HOSE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 28
no.
SET OF SEALS
ALLEN SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 30
no.
2057-4751-013 2057-1015-000 FUSS VOLLST. 4,000 PC 1
FOOT, COMPL.
0010 2057-1467-000 PLATTE 1,000 PC 2
PLATE
MACHINE FOOT
HEX HEAD SCREW
HEX HEAD SCREW
0050 0026-1335-300 SCHEIBE 1,000 PC 2
WASHER / DISK
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 32
no.
0026-1438-170 SPRENGRING 1,000 PC 2
SNAP RING
0020 0003-0644-300 SCHLAGBOLZEN 1,000 PC 2
MALLET
OFFSET SCREWDRIVER
ANNULAR WRENCH
HEXAGON NUT
0200 0015-0082-000 SCHMIERFETT 1,000 PC 2
LUBRICATING GREASE
HEX HEAD SCREW
HEX HEAD SCREW
0340 0019-6351-150 GEWINDESTIFT 1,000 PC 2
THREADED PIN
CLAMP BOLT, COMPL.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 33
no.
HEX HEAD SCREW
0026-1371-300 SCHEIBE 1,000 PC 2
WASHER / DISK
HEXAGON NUT
0500 2058-9939-000 SCHEIBE 1,000 PC 2
WASHER / DISK
2062-9939-000 SCHEIBE 3,000 PC 2
WASHER / DISK
ALLEN SCREW
0620 2063-9823-000 MONTAGERING 1,000 PC 2
MOUNTING RING
HEX HEAD SCREW
HEXAGON NUT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 34
no.
EYE BOLT, COMPL.
2062-9877-010 BOLZEN 1,000 PC 2
BOLT
0013-0393-030 RINGMUTTER 1,000 PC 2
RING NUT
HEXAGON NUT
0024-3579-020 SCHILD 1,000 PC 2
PLATE
HEX HEAD SCREW
WING NUT
0018-4250-030 ROHR 1,000 PC 2
PIPE
HEXAGON NUT
0660 0018-2916-050 DOPPELNIPPEL 1,000 PC 2
DOUBLE NIPPLE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 36
no.
0010 2062-9877-000 BOLZEN 1,000 PC 2
BOLT
0020 2062-9918-000 HEBEL 1,000 PC 2
LEVER
0030 0013-0393-030 RINGMUTTER 1,000 PC 2
RING NUT
0040 2062-9822-000 GLOCKE 1,000 PC 2
BELL-SHAPED PIECE
0050 2062-9939-010 SCHEIBE 1,000 PC 2
WASHER / DISK
0060 0024-3579-020 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 38
no.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 39
no.
SCREW COUPLING
SCREW COUPLING
SCREW COUPLING
0040 0005-4476-630 REDUKTION 1,000 PC 2
REDUCTION
0050 0005-4471-630 REDUKTION 1,000 PC 2
REDUCTION
SCREW COUPLING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 40
no.
2062-4758-000 2063-8800-000 HAUBE VOLLST. 1,000 PC 1
HOOD, COMPL.
0010 2063-8808-000 HAUBE 1,000 PC 2
HOOD
SENSOR BLOCK COMPL.
0080 0018-5956-030 STUTZEN 3,000 PC 2
CONNECTOR
0090 2062-8829-000 SATZ BLENDEN 1,000 PC 1
2062-8473-000 BLENDE 2,000 PC 2
LENS COVER
2062-8473-010 BLENDE 2,000 PC 2
LENS COVER
2062-8473-020 BLENDE 2,000 PC 2
LENS COVER
2062-8473-030 BLENDE 2,000 PC 2
LENS COVER
2062-8473-040 BLENDE 2,000 PC 2
LENS COVER
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 41
no.
2062-8473-050 BLENDE 2,000 PC 2
LENS COVER
0007-1943-630 DICHTRING 2,000 PC 2
GASKET
0110 0018-6615-000 STUTZEN 1,000 PC 2
CONNECTOR
PAN HEAD SCREW
0140 0007-1944-750 DICHTRING 2,000 PC 2
GASKET
NON-RETURN VALVE
COUPLING NUT
PRESSURE GAUGE
SCREW PLUG
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 42
no.
NON-RETURN VALVE
0210 0018-1593-000 ROHRSTUECK 1,000 PC 2
LENGTH OF PIPE
PROTECTIVE HOSE
TERMINAL BOX
ALLEN SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 44
no.
0010 2058-7788-000 BUEGEL 1,000 PC 2
STIRRUP
HEX HEAD SCREW
HEXAGON NUT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 46
no.
SENSOR BLOCK COMPL.
0010 0018-8133-600 MAGNETVENTIL 2,000 PC 1
SOLENOID VALVE
0018-5545-830 MEMBRANE 1,000 PC 2
DIAPHRAGM
0007-2987-830 DICHTRING 3,000 PC 2
GASKET
WATER DETECTOR
0007-1941-630 DICHTRING 1,000 PC 2
GASKET
0040 0007-2501-830 DICHTRING 3,000 PC 2
GASKET
SHUT-OFF VALVE
ALLEN SCREW
0070 0026-1345-300 SCHEIBE 3,000 PC 2
WASHER / DISK
SET OF SPARE PARTS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 47
no.
SET OF SEALS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 49
no.
0020 0007-1944-750 DICHTRING 1,000 PC 2
GASKET
SENSING LIQUID PUMP
0040 0007-3285-750 DICHTRING 1,000 PC 2
GASKET
0050 0007-2925-750 DICHTRING 1,000 PC 2
GASKET
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 51
no.
BOWL, COMPL.
BOWL BOTTOM, COMPL.
0030 0007-3796-760 DICHTRING 1,000 PC 2
GASKET
PISTON GUIDE RING
0070 0007-3169-750 DICHTRING 2,000 PC 2
GASKET
ALLEN SCREW
0090 2063-6503-000 RINGKOLBEN 1,000 PC 2
ANNULAR PISTON
0100 0007-3799-840 DICHTRING 1,000 PC 2
GASKET
0110 0007-3457-790 DICHTRING 1,000 PC 2
GASKET
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 52
no.
0130 0007-2827-790 DICHTRING 1,000 PC 2
GASKET
0140 0007-3216-760 DICHTRING 2,000 PC 2
GASKET
GASKET
ALLEN SCREW
SLIDING PISTON
0190 0007-3798-760 DICHTRING 1,000 PC 2
GASKET
GASKET
0210 2063-6621-000 VERTEILER 1,000 PC 4
DISTRIBUTOR
DISC STACK, COMPL.
2063-6663-000 TELLER VOLLST. 135,000 PC 2
DISC, COMPL.
BLIND DISC
SEPARATING DISC
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 53
no.
BOWL TOP, COMPL.
CYLINDRICAL PIN
0250 0007-3800-910 DICHTRING 1,000 PC 2
GASKET
0260 0007-2625-830 DICHTRING 1,000 PC 2
GASKET
0270 0007-2080-750 DICHTRING 1,000 PC 2
GASKET
LOCK RING
0290 0019-6335-400 GEWINDESTIFT 2,000 PC 2
THREADED PIN
0300 0007-2940-750 DICHTRING 1,000 PC 2
GASKET
0310 0007-2023-750 DICHTRING 2,000 PC 2
GASKET
LOCK RING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 54
no.
SPINDLE SCREW
0360 0007-1941-750 DICHTRING 1,000 PC 2
GASKET
0990 0024-6180-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 56
no.
0024-0070-000 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-565 Page: 57
no.
0024-3531-010 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
Parts Catalogue
Model: OSE 40-0196-067
Bowl S/N: 9054-179
Order-No.: 943911795 / 042000

Tel.: +49 2522 77-0 - Fax: +49 2522 77-2488
Spare parts order

deliveries.
- safety risks,
claims.


chine,
bowl lock ring,
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 3
Explanation
ST = Piece

PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 4
Contents
INSTRUCTION MANUAL
INSTRUCTION MANUAL
2063-1100-000 GESTELL VOLLST. 9 2063-4751-000
FRAME, COMPL.
BRAKE BOLT, COMPL.
2063-3429-000 SPINDEL VOLLST. 21 2063-4753-000
SPINDLE, COMPL.
SET OF DRIVE PARTS
2057-1015-000 FUSS VOLLST. 30 2057-4751-013
FOOT, COMPL.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 5
Contents
2063-8800-000 HAUBE VOLLST. 40 2062-4758-000
HOOD, COMPL.
SENSOR BLOCK COMPL.
2063-2213-000 GREIFER VOLLST. 49 2062-4752-000
2063-6600-510 TROMMEL VOLLST. 51 2062-4756-000
BOWL, COMPL.
0024-0070-000 SCHILD 56
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 6
Contents
0024-3531-010 KLEBESCHILD 57
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 7
no.
INSTRUCTION MANUAL
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 8
no.
INSTRUCTION MANUAL
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 9
no.
FRAME, COMPL.
HEX HEAD SCREW
HEX HEAD SCREW
SCREW PLUG
0080 0007-1796-550 DICHTRING 2,000 PC 2
GASKET
0090 0001-1457-800 SCHAUGLAS 3,000 PC 2
SIGHT GLASS
BRAKE HOUSING
BRAKE BOLT, COMPL.
0130 0021-3525-000 KEGELGRIFF 1,000 PC 2
TAPERED HANDLE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 10
no.
HEX HEAD SCREW
0160 0007-2643-750 DICHTRING 2,000 PC 2
GASKET
0180 0011-8070-000 GELENKLAGER 1,000 PC 2
0190 0007-1958-750 DICHTRING 1,000 PC 2
GASKET
BEARING HOUSING
0210 0026-5741-300 SCHEIBE 16,000 PC 2
WASHER / DISK
HEX HEAD SCREW
0230 0026-1328-300 FEDERRING 7,000 PC 2
LOCK WASHER
SPINDLE, COMPL.
HEX HEAD SCREW
SET OF DRIVE PARTS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 11
no.
0290 2062-1089-000 RING 1,000 PC 2
RING
0300 0007-2035-750 DICHTRING 1,000 PC 2
SKET
0310 2062-1066-000 SCHUTZKAPPE 1,000 PC 2
PROTECTIVE CAP
HEX HEAD SCREW
0330 2063-1464-000 ROHRSTUECK 1,000 PC 2
TUBE PIECE
SCREW COUPLING
0350 0018-3215-030 STUTZEN 1,000 PC 2
CONNECTOR
0370 2062-3266-000 SPINDELKAPPE 1,000 PC 2
SPINDLE CAP
0380 0007-2929-750 DICHTRING 1,000 PC 2
GASKET
0400 0018-6585-710 SCHLAUCH 1,000 PC 2
HOSE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 12
no.
HOSE CLIP
0420 0018-6490-710 SCHLAUCH 1,000 PC 2
HOSE
HOSE CLIP
0470 0018-6620-030 STUTZEN 1,000 PC 2
CONNECTOR
0490 0018-0994-260 STOPFEN 1,000 PC 2
PLUG
HEX HEAD SCREW
HEXAGON NUT
0540 2057-1015-000 FUSS VOLLST. 4,000 PC 1 2057-4751-013
FOOT, COMPL.
0550 0026-1371-400 SCHEIBE 3,000 PC 2
WASHER / DISK
HEX HEAD SCREW
0570 0007-2638-750 DICHTRING 1,000 PC 2
GASKET
0580 0019-5384-050 RINGSCHRAUBE 2,000 PC 2
EYE SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 13
no.
THREADED PLUG
CABLE SLEEVE
0620 2062-1145-000 HALTER 1,000 PC 2
HOLDER
PROXIMITY SENSOR
SCREW COUPLING
0650 0005-1720-900 SOCKEL 2,000 PC 2
BASE
ALLEN SCREW
0670 0005-1455-900 KABELBINDER 4,000 PC 2
CABLE TIE
ALLEN SCREW
0690 0024-4310-010 SATZ SCHILDER 1,000 PC 1
SET OF PLATES
0024-6324-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6327-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 14
no.
0024-6326-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6426-000 SCHILD 1,000 PC 2
PLATE
DECAL "ARROW"
0024-6330-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6329-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6328-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6325-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-3500-010 TYPENSCHILD 1,000 PC 2
TYPE PLATE
0000-0006-162 ENTFAELLT 1,000 PC 7
0026-1571-300 KERBNAGEL 4,000 PC 2
NOTCHED NAIL
0024-6580-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-5380-000 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 15
no.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 17
no.
BRAKE BOLT, COMPL.
0010 2057-1039-000 BREMSBOLZEN 1,000 PC 2
BRAKE BOLT
0020 0021-3301-980 BREMSBELAG 1,000 PC 2
BRAKE LINING
0030 0019-2111-400 SENKSCHRAUBE 1,000 PC 2
COUNTERSUNK SCREW
0040 0019-6310-300 GEWINDESTIFT 1,000 PC 2
THREADED PIN
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 19
no.
NECK BEARING BRIDGE
THREADED PLUG
0050 0026-1289-110 FEDERKOLBEN 6,000 PC 2
SPRING PISTON
0110 0024-6210-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 21
no.
SPINDLE, COMPL.
0010 2063-3410-000 SPINDEL 1,000 PC 2
SPINDLE
0030 0008-5009-050 ABSTANDSRING 1,000 PC 2
SPACING RING
0050 0026-2499-000 STELLRING 1,000 PC 2
SET COLLAR
0060 0019-8964-400 GEWINDESTIFT 4,000 PC 2
THREADED PIN
CYLINDRICAL PIN
0100 0026-0314-170 SPANNSTIFT 1,000 PC 2
SPRING DOWEL SLEEVE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 23
no.
SET OF DRIVE PARTS
0020 0026-1353-030 SCHEIBE 1,000 PC 2
WASHER / DISK
HEX HEAD SCREW
DRIVE BELT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 25
no.
CLUTCH PULLEY
SPACER SLEEVE
SECURING RING
SECURING RING
FLAT-BELT PULLEY
ALLEN SCREW
CLUTCH SHOE
0100 2057-3367-000 SCHEIBE 1,000 PC 2
WASHER / DISK
SECURING RING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 27
no.
0010 0018-7614-920 DRUCKREGLER 1,000 PC 2
PRESSURE REGULATOR
BALL VALVE
0018-1763-280 GRIFF 1,000 PC 2
HANDLE
PRESSURE GAUGE
FILTER INSERT
0070 0018-6654-010 MAGNETSPULE 2,000 PC 2
SOLENOID
0080 0018-6654-040 GEHAEUSE 2,000 PC 2
HOUSING
0090 0018-5947-820 MEMBRANE 2,000 PC 2
DIAPHRAGM
0100 0018-7614-930 MAGNETKERN 2,000 PC 2
SOLENOID CORE
COUPLER SOCKET
0130 0018-7614-910 SCHLAUCH 1,000 PC 2
HOSE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 28
no.
SET OF SEALS
ALLEN SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 30
no.
2057-4751-013 2057-1015-000 FUSS VOLLST. 4,000 PC 1
FOOT, COMPL.
0010 2057-1467-000 PLATTE 1,000 PC 2
PLATE
MACHINE FOOT
HEX HEAD SCREW
HEX HEAD SCREW
0050 0026-1335-300 SCHEIBE 1,000 PC 2
WASHER / DISK
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 32
no.
0026-1438-170 SPRENGRING 1,000 PC 2
SNAP RING
0020 0003-0644-300 SCHLAGBOLZEN 1,000 PC 2
MALLET
OFFSET SCREWDRIVER
ANNULAR WRENCH
HEXAGON NUT
0200 0015-0082-000 SCHMIERFETT 1,000 PC 2
LUBRICATING GREASE
HEX HEAD SCREW
HEX HEAD SCREW
0340 0019-6351-150 GEWINDESTIFT 1,000 PC 2
THREADED PIN
CLAMP BOLT, COMPL.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 33
no.
HEX HEAD SCREW
0026-1371-300 SCHEIBE 1,000 PC 2
WASHER / DISK
HEXAGON NUT
0500 2058-9939-000 SCHEIBE 1,000 PC 2
WASHER / DISK
2062-9939-000 SCHEIBE 3,000 PC 2
WASHER / DISK
ALLEN SCREW
0620 2063-9823-000 MONTAGERING 1,000 PC 2
MOUNTING RING
HEX HEAD SCREW
HEXAGON NUT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 34
no.
EYE BOLT, COMPL.
2062-9877-010 BOLZEN 1,000 PC 2
BOLT
0013-0393-030 RINGMUTTER 1,000 PC 2
RING NUT
HEXAGON NUT
0024-3579-020 SCHILD 1,000 PC 2
PLATE
HEX HEAD SCREW
WING NUT
0018-4250-030 ROHR 1,000 PC 2
PIPE
HEXAGON NUT
0660 0018-2916-050 DOPPELNIPPEL 1,000 PC 2
DOUBLE NIPPLE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 36
no.
0010 2062-9877-000 BOLZEN 1,000 PC 2
BOLT
0020 2062-9918-000 HEBEL 1,000 PC 2
LEVER
0030 0013-0393-030 RINGMUTTER 1,000 PC 2
RING NUT
0040 2062-9822-000 GLOCKE 1,000 PC 2
BELL-SHAPED PIECE
0050 2062-9939-010 SCHEIBE 1,000 PC 2
WASHER / DISK
0060 0024-3579-020 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 38
no.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 39
no.
SCREW COUPLING
SCREW COUPLING
SCREW COUPLING
0040 0005-4476-630 REDUKTION 1,000 PC 2
REDUCTION
0050 0005-4471-630 REDUKTION 1,000 PC 2
REDUCTION
SCREW COUPLING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 40
no.
2062-4758-000 2063-8800-000 HAUBE VOLLST. 1,000 PC 1
HOOD, COMPL.
0010 2063-8808-000 HAUBE 1,000 PC 2
HOOD
SENSOR BLOCK COMPL.
0080 0018-5956-030 STUTZEN 3,000 PC 2
CONNECTOR
0090 2062-8829-000 SATZ BLENDEN 1,000 PC 1
2062-8473-000 BLENDE 2,000 PC 2
LENS COVER
2062-8473-010 BLENDE 2,000 PC 2
LENS COVER
2062-8473-020 BLENDE 2,000 PC 2
LENS COVER
2062-8473-030 BLENDE 2,000 PC 2
LENS COVER
2062-8473-040 BLENDE 2,000 PC 2
LENS COVER
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 41
no.
2062-8473-050 BLENDE 2,000 PC 2
LENS COVER
0007-1943-630 DICHTRING 2,000 PC 2
GASKET
0110 0018-6615-000 STUTZEN 1,000 PC 2
CONNECTOR
PAN HEAD SCREW
0140 0007-1944-750 DICHTRING 2,000 PC 2
GASKET
NON-RETURN VALVE
COUPLING NUT
PRESSURE GAUGE
SCREW PLUG
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 42
no.
NON-RETURN VALVE
0210 0018-1593-000 ROHRSTUECK 1,000 PC 2
LENGTH OF PIPE
PROTECTIVE HOSE
TERMINAL BOX
ALLEN SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 44
no.
0010 2058-7788-000 BUEGEL 1,000 PC 2
STIRRUP
HEX HEAD SCREW
HEXAGON NUT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 46
no.
SENSOR BLOCK COMPL.
0010 0018-8133-600 MAGNETVENTIL 2,000 PC 1
SOLENOID VALVE
0018-5545-830 MEMBRANE 1,000 PC 2
DIAPHRAGM
0007-2987-830 DICHTRING 3,000 PC 2
GASKET
WATER DETECTOR
0007-1941-630 DICHTRING 1,000 PC 2
GASKET
0040 0007-2501-830 DICHTRING 3,000 PC 2
GASKET
SHUT-OFF VALVE
ALLEN SCREW
0070 0026-1345-300 SCHEIBE 3,000 PC 2
WASHER / DISK
SET OF SPARE PARTS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 47
no.
SET OF SEALS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 49
no.
0020 0007-1944-750 DICHTRING 1,000 PC 2
GASKET
SENSING LIQUID PUMP
0040 0007-3285-750 DICHTRING 1,000 PC 2
GASKET
0050 0007-2925-750 DICHTRING 1,000 PC 2
GASKET
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 51
no.
BOWL, COMPL.
BOWL BOTTOM, COMPL.
0030 0007-3796-760 DICHTRING 1,000 PC 2
GASKET
PISTON GUIDE RING
0070 0007-3169-750 DICHTRING 2,000 PC 2
GASKET
ALLEN SCREW
0090 2063-6503-000 RINGKOLBEN 1,000 PC 2
ANNULAR PISTON
0100 0007-3799-840 DICHTRING 1,000 PC 2
GASKET
0110 0007-3457-790 DICHTRING 1,000 PC 2
GASKET
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 52
no.
0130 0007-2827-790 DICHTRING 1,000 PC 2
GASKET
0140 0007-3216-760 DICHTRING 2,000 PC 2
GASKET
GASKET
ALLEN SCREW
SLIDING PISTON
0190 0007-3798-760 DICHTRING 1,000 PC 2
GASKET
GASKET
0210 2063-6621-000 VERTEILER 1,000 PC 4
DISTRIBUTOR
DISC STACK, COMPL.
2063-6663-000 TELLER VOLLST. 135,000 PC 2
DISC, COMPL.
BLIND DISC
SEPARATING DISC
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 53
no.
BOWL TOP, COMPL.
CYLINDRICAL PIN
0250 0007-3800-910 DICHTRING 1,000 PC 2
GASKET
0260 0007-2625-830 DICHTRING 1,000 PC 2
GASKET
0270 0007-2080-750 DICHTRING 1,000 PC 2
GASKET
LOCK RING
0290 0019-6335-400 GEWINDESTIFT 2,000 PC 2
THREADED PIN
0300 0007-2940-750 DICHTRING 1,000 PC 2
GASKET
0310 0007-2023-750 DICHTRING 2,000 PC 2
GASKET
LOCK RING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 54
no.
SPINDLE SCREW
0360 0007-1941-750 DICHTRING 1,000 PC 2
GASKET
0990 0024-6180-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 56
no.
0024-0070-000 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-571 Page: 57
no.
0024-3531-010 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
Parts Catalogue
Model: OSE 40-0196-067
Bowl S/N: 9054-180
Order-No.: 943911795 / 052000

Tel.: +49 2522 77-0 - Fax: +49 2522 77-2488
Spare parts order

deliveries.
- safety risks,
claims.


chine,
bowl lock ring,
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 3
Explanation
ST = Piece

PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 4
Contents
INSTRUCTION MANUAL
INSTRUCTION MANUAL
2063-1100-000 GESTELL VOLLST. 9 2063-4751-000
FRAME, COMPL.
BRAKE BOLT, COMPL.
2063-3429-000 SPINDEL VOLLST. 21 2063-4753-000
SPINDLE, COMPL.
SET OF DRIVE PARTS
2057-1015-000 FUSS VOLLST. 30 2057-4751-013
FOOT, COMPL.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 5
Contents
2063-8800-000 HAUBE VOLLST. 40 2062-4758-000
HOOD, COMPL.
SENSOR BLOCK COMPL.
2063-2213-000 GREIFER VOLLST. 49 2062-4752-000
2063-6600-510 TROMMEL VOLLST. 51 2062-4756-000
BOWL, COMPL.
0024-0070-000 SCHILD 56
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 6
Contents
0024-3531-010 KLEBESCHILD 57
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 7
no.
INSTRUCTION MANUAL
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 8
no.
INSTRUCTION MANUAL
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 9
no.
FRAME, COMPL.
HEX HEAD SCREW
HEX HEAD SCREW
SCREW PLUG
0080 0007-1796-550 DICHTRING 2,000 PC 2
GASKET
0090 0001-1457-800 SCHAUGLAS 3,000 PC 2
SIGHT GLASS
BRAKE HOUSING
BRAKE BOLT, COMPL.
0130 0021-3525-000 KEGELGRIFF 1,000 PC 2
TAPERED HANDLE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 10
no.
HEX HEAD SCREW
0160 0007-2643-750 DICHTRING 2,000 PC 2
GASKET
0180 0011-8070-000 GELENKLAGER 1,000 PC 2
0190 0007-1958-750 DICHTRING 1,000 PC 2
GASKET
BEARING HOUSING
0210 0026-5741-300 SCHEIBE 16,000 PC 2
WASHER / DISK
HEX HEAD SCREW
0230 0026-1328-300 FEDERRING 7,000 PC 2
LOCK WASHER
SPINDLE, COMPL.
HEX HEAD SCREW
SET OF DRIVE PARTS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 11
no.
0290 2062-1089-000 RING 1,000 PC 2
RING
0300 0007-2035-750 DICHTRING 1,000 PC 2
SKET
0310 2062-1066-000 SCHUTZKAPPE 1,000 PC 2
PROTECTIVE CAP
HEX HEAD SCREW
0330 2063-1464-000 ROHRSTUECK 1,000 PC 2
TUBE PIECE
SCREW COUPLING
0350 0018-3215-030 STUTZEN 1,000 PC 2
CONNECTOR
0370 2062-3266-000 SPINDELKAPPE 1,000 PC 2
SPINDLE CAP
0380 0007-2929-750 DICHTRING 1,000 PC 2
GASKET
0400 0018-6585-710 SCHLAUCH 1,000 PC 2
HOSE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 12
no.
HOSE CLIP
0420 0018-6490-710 SCHLAUCH 1,000 PC 2
HOSE
HOSE CLIP
0470 0018-6620-030 STUTZEN 1,000 PC 2
CONNECTOR
0490 0018-0994-260 STOPFEN 1,000 PC 2
PLUG
HEX HEAD SCREW
HEXAGON NUT
0540 2057-1015-000 FUSS VOLLST. 4,000 PC 1 2057-4751-013
FOOT, COMPL.
0550 0026-1371-400 SCHEIBE 3,000 PC 2
WASHER / DISK
HEX HEAD SCREW
0570 0007-2638-750 DICHTRING 1,000 PC 2
GASKET
0580 0019-5384-050 RINGSCHRAUBE 2,000 PC 2
EYE SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 13
no.
THREADED PLUG
CABLE SLEEVE
0620 2062-1145-000 HALTER 1,000 PC 2
HOLDER
PROXIMITY SENSOR
SCREW COUPLING
0650 0005-1720-900 SOCKEL 2,000 PC 2
BASE
ALLEN SCREW
0670 0005-1455-900 KABELBINDER 4,000 PC 2
CABLE TIE
ALLEN SCREW
0690 0024-4310-010 SATZ SCHILDER 1,000 PC 1
SET OF PLATES
0024-6324-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6327-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 14
no.
0024-6326-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6426-000 SCHILD 1,000 PC 2
PLATE
DECAL "ARROW"
0024-6330-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6329-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6328-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6325-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-3500-010 TYPENSCHILD 1,000 PC 2
TYPE PLATE
0000-0006-162 ENTFAELLT 1,000 PC 7
0026-1571-300 KERBNAGEL 4,000 PC 2
NOTCHED NAIL
0024-6580-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-5380-000 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 15
no.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 17
no.
BRAKE BOLT, COMPL.
0010 2057-1039-000 BREMSBOLZEN 1,000 PC 2
BRAKE BOLT
0020 0021-3301-980 BREMSBELAG 1,000 PC 2
BRAKE LINING
0030 0019-2111-400 SENKSCHRAUBE 1,000 PC 2
COUNTERSUNK SCREW
0040 0019-6310-300 GEWINDESTIFT 1,000 PC 2
THREADED PIN
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 19
no.
NECK BEARING BRIDGE
THREADED PLUG
0050 0026-1289-110 FEDERKOLBEN 6,000 PC 2
SPRING PISTON
0110 0024-6210-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 21
no.
SPINDLE, COMPL.
0010 2063-3410-000 SPINDEL 1,000 PC 2
SPINDLE
0030 0008-5009-050 ABSTANDSRING 1,000 PC 2
SPACING RING
0050 0026-2499-000 STELLRING 1,000 PC 2
SET COLLAR
0060 0019-8964-400 GEWINDESTIFT 4,000 PC 2
THREADED PIN
CYLINDRICAL PIN
0100 0026-0314-170 SPANNSTIFT 1,000 PC 2
SPRING DOWEL SLEEVE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 23
no.
SET OF DRIVE PARTS
0020 0026-1353-030 SCHEIBE 1,000 PC 2
WASHER / DISK
HEX HEAD SCREW
DRIVE BELT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 25
no.
CLUTCH PULLEY
SPACER SLEEVE
SECURING RING
SECURING RING
FLAT-BELT PULLEY
ALLEN SCREW
CLUTCH SHOE
0100 2057-3367-000 SCHEIBE 1,000 PC 2
WASHER / DISK
SECURING RING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 27
no.
0010 0018-7614-920 DRUCKREGLER 1,000 PC 2
PRESSURE REGULATOR
BALL VALVE
0018-1763-280 GRIFF 1,000 PC 2
HANDLE
PRESSURE GAUGE
FILTER INSERT
0070 0018-6654-010 MAGNETSPULE 2,000 PC 2
SOLENOID
0080 0018-6654-040 GEHAEUSE 2,000 PC 2
HOUSING
0090 0018-5947-820 MEMBRANE 2,000 PC 2
DIAPHRAGM
0100 0018-7614-930 MAGNETKERN 2,000 PC 2
SOLENOID CORE
COUPLER SOCKET
0130 0018-7614-910 SCHLAUCH 1,000 PC 2
HOSE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 28
no.
SET OF SEALS
ALLEN SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 30
no.
2057-4751-013 2057-1015-000 FUSS VOLLST. 4,000 PC 1
FOOT, COMPL.
0010 2057-1467-000 PLATTE 1,000 PC 2
PLATE
MACHINE FOOT
HEX HEAD SCREW
HEX HEAD SCREW
0050 0026-1335-300 SCHEIBE 1,000 PC 2
WASHER / DISK
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 32
no.
0026-1438-170 SPRENGRING 1,000 PC 2
SNAP RING
0020 0003-0644-300 SCHLAGBOLZEN 1,000 PC 2
MALLET
OFFSET SCREWDRIVER
ANNULAR WRENCH
HEXAGON NUT
0200 0015-0082-000 SCHMIERFETT 1,000 PC 2
LUBRICATING GREASE
HEX HEAD SCREW
HEX HEAD SCREW
0340 0019-6351-150 GEWINDESTIFT 1,000 PC 2
THREADED PIN
CLAMP BOLT, COMPL.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 33
no.
HEX HEAD SCREW
0026-1371-300 SCHEIBE 1,000 PC 2
WASHER / DISK
HEXAGON NUT
0500 2058-9939-000 SCHEIBE 1,000 PC 2
WASHER / DISK
2062-9939-000 SCHEIBE 3,000 PC 2
WASHER / DISK
ALLEN SCREW
0620 2063-9823-000 MONTAGERING 1,000 PC 2
MOUNTING RING
HEX HEAD SCREW
HEXAGON NUT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 34
no.
EYE BOLT, COMPL.
2062-9877-010 BOLZEN 1,000 PC 2
BOLT
0013-0393-030 RINGMUTTER 1,000 PC 2
RING NUT
HEXAGON NUT
0024-3579-020 SCHILD 1,000 PC 2
PLATE
HEX HEAD SCREW
WING NUT
0018-4250-030 ROHR 1,000 PC 2
PIPE
HEXAGON NUT
0660 0018-2916-050 DOPPELNIPPEL 1,000 PC 2
DOUBLE NIPPLE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 36
no.
0010 2062-9877-000 BOLZEN 1,000 PC 2
BOLT
0020 2062-9918-000 HEBEL 1,000 PC 2
LEVER
0030 0013-0393-030 RINGMUTTER 1,000 PC 2
RING NUT
0040 2062-9822-000 GLOCKE 1,000 PC 2
BELL-SHAPED PIECE
0050 2062-9939-010 SCHEIBE 1,000 PC 2
WASHER / DISK
0060 0024-3579-020 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 38
no.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 39
no.
SCREW COUPLING
SCREW COUPLING
SCREW COUPLING
0040 0005-4476-630 REDUKTION 1,000 PC 2
REDUCTION
0050 0005-4471-630 REDUKTION 1,000 PC 2
REDUCTION
SCREW COUPLING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 40
no.
2062-4758-000 2063-8800-000 HAUBE VOLLST. 1,000 PC 1
HOOD, COMPL.
0010 2063-8808-000 HAUBE 1,000 PC 2
HOOD
SENSOR BLOCK COMPL.
0080 0018-5956-030 STUTZEN 3,000 PC 2
CONNECTOR
0090 2062-8829-000 SATZ BLENDEN 1,000 PC 1
2062-8473-000 BLENDE 2,000 PC 2
LENS COVER
2062-8473-010 BLENDE 2,000 PC 2
LENS COVER
2062-8473-020 BLENDE 2,000 PC 2
LENS COVER
2062-8473-030 BLENDE 2,000 PC 2
LENS COVER
2062-8473-040 BLENDE 2,000 PC 2
LENS COVER
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 41
no.
2062-8473-050 BLENDE 2,000 PC 2
LENS COVER
0007-1943-630 DICHTRING 2,000 PC 2
GASKET
0110 0018-6615-000 STUTZEN 1,000 PC 2
CONNECTOR
PAN HEAD SCREW
0140 0007-1944-750 DICHTRING 2,000 PC 2
GASKET
NON-RETURN VALVE
COUPLING NUT
PRESSURE GAUGE
SCREW PLUG
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 42
no.
NON-RETURN VALVE
0210 0018-1593-000 ROHRSTUECK 1,000 PC 2
LENGTH OF PIPE
PROTECTIVE HOSE
TERMINAL BOX
ALLEN SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 44
no.
0010 2058-7788-000 BUEGEL 1,000 PC 2
STIRRUP
HEX HEAD SCREW
HEXAGON NUT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 46
no.
SENSOR BLOCK COMPL.
0010 0018-8133-600 MAGNETVENTIL 2,000 PC 1
SOLENOID VALVE
0018-5545-830 MEMBRANE 1,000 PC 2
DIAPHRAGM
0007-2987-830 DICHTRING 3,000 PC 2
GASKET
WATER DETECTOR
0007-1941-630 DICHTRING 1,000 PC 2
GASKET
0040 0007-2501-830 DICHTRING 3,000 PC 2
GASKET
SHUT-OFF VALVE
ALLEN SCREW
0070 0026-1345-300 SCHEIBE 3,000 PC 2
WASHER / DISK
SET OF SPARE PARTS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 47
no.
SET OF SEALS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 49
no.
0020 0007-1944-750 DICHTRING 1,000 PC 2
GASKET
SENSING LIQUID PUMP
0040 0007-3285-750 DICHTRING 1,000 PC 2
GASKET
0050 0007-2925-750 DICHTRING 1,000 PC 2
GASKET
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 51
no.
BOWL, COMPL.
BOWL BOTTOM, COMPL.
0030 0007-3796-760 DICHTRING 1,000 PC 2
GASKET
PISTON GUIDE RING
0070 0007-3169-750 DICHTRING 2,000 PC 2
GASKET
ALLEN SCREW
0090 2063-6503-000 RINGKOLBEN 1,000 PC 2
ANNULAR PISTON
0100 0007-3799-840 DICHTRING 1,000 PC 2
GASKET
0110 0007-3457-790 DICHTRING 1,000 PC 2
GASKET
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 52
no.
0130 0007-2827-790 DICHTRING 1,000 PC 2
GASKET
0140 0007-3216-760 DICHTRING 2,000 PC 2
GASKET
GASKET
ALLEN SCREW
SLIDING PISTON
0190 0007-3798-760 DICHTRING 1,000 PC 2
GASKET
GASKET
0210 2063-6621-000 VERTEILER 1,000 PC 4
DISTRIBUTOR
DISC STACK, COMPL.
2063-6663-000 TELLER VOLLST. 135,000 PC 2
DISC, COMPL.
BLIND DISC
SEPARATING DISC
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 53
no.
BOWL TOP, COMPL.
CYLINDRICAL PIN
0250 0007-3800-910 DICHTRING 1,000 PC 2
GASKET
0260 0007-2625-830 DICHTRING 1,000 PC 2
GASKET
0270 0007-2080-750 DICHTRING 1,000 PC 2
GASKET
LOCK RING
0290 0019-6335-400 GEWINDESTIFT 2,000 PC 2
THREADED PIN
0300 0007-2940-750 DICHTRING 1,000 PC 2
GASKET
0310 0007-2023-750 DICHTRING 2,000 PC 2
GASKET
LOCK RING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 54
no.
SPINDLE SCREW
0360 0007-1941-750 DICHTRING 1,000 PC 2
GASKET
0990 0024-6180-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 56
no.
0024-0070-000 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-577 Page: 57
no.
0024-3531-010 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
Parts Catalogue
Model: OSE 40-0196-067
Bowl S/N: 9054-181
Order-No.: 943911795 / 062000

Tel.: +49 2522 77-0 - Fax: +49 2522 77-2488
Spare parts order

deliveries.
- safety risks,
claims.


chine,
bowl lock ring,
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 3
Explanation
ST = Piece

PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 4
Contents
INSTRUCTION MANUAL
INSTRUCTION MANUAL
2063-1100-000 GESTELL VOLLST. 9 2063-4751-000
FRAME, COMPL.
BRAKE BOLT, COMPL.
2063-3429-000 SPINDEL VOLLST. 21 2063-4753-000
SPINDLE, COMPL.
SET OF DRIVE PARTS
2057-1015-000 FUSS VOLLST. 30 2057-4751-013
FOOT, COMPL.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 5
Contents
2063-8800-000 HAUBE VOLLST. 40 2062-4758-000
HOOD, COMPL.
SENSOR BLOCK COMPL.
2063-2213-000 GREIFER VOLLST. 49 2062-4752-000
2063-6600-510 TROMMEL VOLLST. 51 2062-4756-000
BOWL, COMPL.
0024-0070-000 SCHILD 56
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 6
Contents
0024-3531-010 KLEBESCHILD 57
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 7
no.
INSTRUCTION MANUAL
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 8
no.
INSTRUCTION MANUAL
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 9
no.
FRAME, COMPL.
HEX HEAD SCREW
HEX HEAD SCREW
SCREW PLUG
0080 0007-1796-550 DICHTRING 2,000 PC 2
GASKET
0090 0001-1457-800 SCHAUGLAS 3,000 PC 2
SIGHT GLASS
BRAKE HOUSING
BRAKE BOLT, COMPL.
0130 0021-3525-000 KEGELGRIFF 1,000 PC 2
TAPERED HANDLE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 10
no.
HEX HEAD SCREW
0160 0007-2643-750 DICHTRING 2,000 PC 2
GASKET
0180 0011-8070-000 GELENKLAGER 1,000 PC 2
0190 0007-1958-750 DICHTRING 1,000 PC 2
GASKET
BEARING HOUSING
0210 0026-5741-300 SCHEIBE 16,000 PC 2
WASHER / DISK
HEX HEAD SCREW
0230 0026-1328-300 FEDERRING 7,000 PC 2
LOCK WASHER
SPINDLE, COMPL.
HEX HEAD SCREW
SET OF DRIVE PARTS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 11
no.
0290 2062-1089-000 RING 1,000 PC 2
RING
0300 0007-2035-750 DICHTRING 1,000 PC 2
SKET
0310 2062-1066-000 SCHUTZKAPPE 1,000 PC 2
PROTECTIVE CAP
HEX HEAD SCREW
0330 2063-1464-000 ROHRSTUECK 1,000 PC 2
TUBE PIECE
SCREW COUPLING
0350 0018-3215-030 STUTZEN 1,000 PC 2
CONNECTOR
0370 2062-3266-000 SPINDELKAPPE 1,000 PC 2
SPINDLE CAP
0380 0007-2929-750 DICHTRING 1,000 PC 2
GASKET
0400 0018-6585-710 SCHLAUCH 1,000 PC 2
HOSE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 12
no.
HOSE CLIP
0420 0018-6490-710 SCHLAUCH 1,000 PC 2
HOSE
HOSE CLIP
0470 0018-6620-030 STUTZEN 1,000 PC 2
CONNECTOR
0490 0018-0994-260 STOPFEN 1,000 PC 2
PLUG
HEX HEAD SCREW
HEXAGON NUT
0540 2057-1015-000 FUSS VOLLST. 4,000 PC 1 2057-4751-013
FOOT, COMPL.
0550 0026-1371-400 SCHEIBE 3,000 PC 2
WASHER / DISK
HEX HEAD SCREW
0570 0007-2638-750 DICHTRING 1,000 PC 2
GASKET
0580 0019-5384-050 RINGSCHRAUBE 2,000 PC 2
EYE SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 13
no.
THREADED PLUG
CABLE SLEEVE
0620 2062-1145-000 HALTER 1,000 PC 2
HOLDER
PROXIMITY SENSOR
SCREW COUPLING
0650 0005-1720-900 SOCKEL 2,000 PC 2
BASE
ALLEN SCREW
0670 0005-1455-900 KABELBINDER 4,000 PC 2
CABLE TIE
ALLEN SCREW
0690 0024-4310-010 SATZ SCHILDER 1,000 PC 1
SET OF PLATES
0024-6324-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6327-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 14
no.
0024-6326-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6426-000 SCHILD 1,000 PC 2
PLATE
DECAL "ARROW"
0024-6330-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6329-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6328-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-6325-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-3500-010 TYPENSCHILD 1,000 PC 2
TYPE PLATE
0000-0006-162 ENTFAELLT 1,000 PC 7
0026-1571-300 KERBNAGEL 4,000 PC 2
NOTCHED NAIL
0024-6580-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
0024-5380-000 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 15
no.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 17
no.
BRAKE BOLT, COMPL.
0010 2057-1039-000 BREMSBOLZEN 1,000 PC 2
BRAKE BOLT
0020 0021-3301-980 BREMSBELAG 1,000 PC 2
BRAKE LINING
0030 0019-2111-400 SENKSCHRAUBE 1,000 PC 2
COUNTERSUNK SCREW
0040 0019-6310-300 GEWINDESTIFT 1,000 PC 2
THREADED PIN
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 19
no.
NECK BEARING BRIDGE
THREADED PLUG
0050 0026-1289-110 FEDERKOLBEN 6,000 PC 2
SPRING PISTON
0110 0024-6210-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 21
no.
SPINDLE, COMPL.
0010 2063-3410-000 SPINDEL 1,000 PC 2
SPINDLE
0030 0008-5009-050 ABSTANDSRING 1,000 PC 2
SPACING RING
0050 0026-2499-000 STELLRING 1,000 PC 2
SET COLLAR
0060 0019-8964-400 GEWINDESTIFT 4,000 PC 2
THREADED PIN
CYLINDRICAL PIN
0100 0026-0314-170 SPANNSTIFT 1,000 PC 2
SPRING DOWEL SLEEVE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 23
no.
SET OF DRIVE PARTS
0020 0026-1353-030 SCHEIBE 1,000 PC 2
WASHER / DISK
HEX HEAD SCREW
DRIVE BELT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 25
no.
CLUTCH PULLEY
SPACER SLEEVE
SECURING RING
SECURING RING
FLAT-BELT PULLEY
ALLEN SCREW
CLUTCH SHOE
0100 2057-3367-000 SCHEIBE 1,000 PC 2
WASHER / DISK
SECURING RING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 27
no.
0010 0018-7614-920 DRUCKREGLER 1,000 PC 2
PRESSURE REGULATOR
BALL VALVE
0018-1763-280 GRIFF 1,000 PC 2
HANDLE
PRESSURE GAUGE
FILTER INSERT
0070 0018-6654-010 MAGNETSPULE 2,000 PC 2
SOLENOID
0080 0018-6654-040 GEHAEUSE 2,000 PC 2
HOUSING
0090 0018-5947-820 MEMBRANE 2,000 PC 2
DIAPHRAGM
0100 0018-7614-930 MAGNETKERN 2,000 PC 2
SOLENOID CORE
COUPLER SOCKET
0130 0018-7614-910 SCHLAUCH 1,000 PC 2
HOSE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 28
no.
SET OF SEALS
ALLEN SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 30
no.
2057-4751-013 2057-1015-000 FUSS VOLLST. 4,000 PC 1
FOOT, COMPL.
0010 2057-1467-000 PLATTE 1,000 PC 2
PLATE
MACHINE FOOT
HEX HEAD SCREW
HEX HEAD SCREW
0050 0026-1335-300 SCHEIBE 1,000 PC 2
WASHER / DISK
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 32
no.
0026-1438-170 SPRENGRING 1,000 PC 2
SNAP RING
0020 0003-0644-300 SCHLAGBOLZEN 1,000 PC 2
MALLET
OFFSET SCREWDRIVER
ANNULAR WRENCH
HEXAGON NUT
0200 0015-0082-000 SCHMIERFETT 1,000 PC 2
LUBRICATING GREASE
HEX HEAD SCREW
HEX HEAD SCREW
0340 0019-6351-150 GEWINDESTIFT 1,000 PC 2
THREADED PIN
CLAMP BOLT, COMPL.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 33
no.
HEX HEAD SCREW
0026-1371-300 SCHEIBE 1,000 PC 2
WASHER / DISK
HEXAGON NUT
0500 2058-9939-000 SCHEIBE 1,000 PC 2
WASHER / DISK
2062-9939-000 SCHEIBE 3,000 PC 2
WASHER / DISK
ALLEN SCREW
0620 2063-9823-000 MONTAGERING 1,000 PC 2
MOUNTING RING
HEX HEAD SCREW
HEXAGON NUT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 34
no.
EYE BOLT, COMPL.
2062-9877-010 BOLZEN 1,000 PC 2
BOLT
0013-0393-030 RINGMUTTER 1,000 PC 2
RING NUT
HEXAGON NUT
0024-3579-020 SCHILD 1,000 PC 2
PLATE
HEX HEAD SCREW
WING NUT
0018-4250-030 ROHR 1,000 PC 2
PIPE
HEXAGON NUT
0660 0018-2916-050 DOPPELNIPPEL 1,000 PC 2
DOUBLE NIPPLE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 36
no.
0010 2062-9877-000 BOLZEN 1,000 PC 2
BOLT
0020 2062-9918-000 HEBEL 1,000 PC 2
LEVER
0030 0013-0393-030 RINGMUTTER 1,000 PC 2
RING NUT
0040 2062-9822-000 GLOCKE 1,000 PC 2
BELL-SHAPED PIECE
0050 2062-9939-010 SCHEIBE 1,000 PC 2
WASHER / DISK
0060 0024-3579-020 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 38
no.
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 39
no.
SCREW COUPLING
SCREW COUPLING
SCREW COUPLING
0040 0005-4476-630 REDUKTION 1,000 PC 2
REDUCTION
0050 0005-4471-630 REDUKTION 1,000 PC 2
REDUCTION
SCREW COUPLING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 40
no.
2062-4758-000 2063-8800-000 HAUBE VOLLST. 1,000 PC 1
HOOD, COMPL.
0010 2063-8808-000 HAUBE 1,000 PC 2
HOOD
SENSOR BLOCK COMPL.
0080 0018-5956-030 STUTZEN 3,000 PC 2
CONNECTOR
0090 2062-8829-000 SATZ BLENDEN 1,000 PC 1
2062-8473-000 BLENDE 2,000 PC 2
LENS COVER
2062-8473-010 BLENDE 2,000 PC 2
LENS COVER
2062-8473-020 BLENDE 2,000 PC 2
LENS COVER
2062-8473-030 BLENDE 2,000 PC 2
LENS COVER
2062-8473-040 BLENDE 2,000 PC 2
LENS COVER
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 41
no.
2062-8473-050 BLENDE 2,000 PC 2
LENS COVER
0007-1943-630 DICHTRING 2,000 PC 2
GASKET
0110 0018-6615-000 STUTZEN 1,000 PC 2
CONNECTOR
PAN HEAD SCREW
0140 0007-1944-750 DICHTRING 2,000 PC 2
GASKET
NON-RETURN VALVE
COUPLING NUT
PRESSURE GAUGE
SCREW PLUG
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 42
no.
NON-RETURN VALVE
0210 0018-1593-000 ROHRSTUECK 1,000 PC 2
LENGTH OF PIPE
PROTECTIVE HOSE
TERMINAL BOX
ALLEN SCREW
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 44
no.
0010 2058-7788-000 BUEGEL 1,000 PC 2
STIRRUP
HEX HEAD SCREW
HEXAGON NUT
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 46
no.
SENSOR BLOCK COMPL.
0010 0018-8133-600 MAGNETVENTIL 2,000 PC 1
SOLENOID VALVE
0018-5545-830 MEMBRANE 1,000 PC 2
DIAPHRAGM
0007-2987-830 DICHTRING 3,000 PC 2
GASKET
WATER DETECTOR
0007-1941-630 DICHTRING 1,000 PC 2
GASKET
0040 0007-2501-830 DICHTRING 3,000 PC 2
GASKET
SHUT-OFF VALVE
ALLEN SCREW
0070 0026-1345-300 SCHEIBE 3,000 PC 2
WASHER / DISK
SET OF SPARE PARTS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 47
no.
SET OF SEALS
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 49
no.
0020 0007-1944-750 DICHTRING 1,000 PC 2
GASKET
SENSING LIQUID PUMP
0040 0007-3285-750 DICHTRING 1,000 PC 2
GASKET
0050 0007-2925-750 DICHTRING 1,000 PC 2
GASKET
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 51
no.
BOWL, COMPL.
BOWL BOTTOM, COMPL.
0030 0007-3796-760 DICHTRING 1,000 PC 2
GASKET
PISTON GUIDE RING
0070 0007-3169-750 DICHTRING 2,000 PC 2
GASKET
ALLEN SCREW
0090 2063-6503-000 RINGKOLBEN 1,000 PC 2
ANNULAR PISTON
0100 0007-3799-840 DICHTRING 1,000 PC 2
GASKET
0110 0007-3457-790 DICHTRING 1,000 PC 2
GASKET
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 52
no.
0130 0007-2827-790 DICHTRING 1,000 PC 2
GASKET
0140 0007-3216-760 DICHTRING 2,000 PC 2
GASKET
GASKET
ALLEN SCREW
SLIDING PISTON
0190 0007-3798-760 DICHTRING 1,000 PC 2
GASKET
GASKET
0210 2063-6621-000 VERTEILER 1,000 PC 4
DISTRIBUTOR
DISC STACK, COMPL.
2063-6663-000 TELLER VOLLST. 135,000 PC 2
DISC, COMPL.
BLIND DISC
SEPARATING DISC
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 53
no.
BOWL TOP, COMPL.
CYLINDRICAL PIN
0250 0007-3800-910 DICHTRING 1,000 PC 2
GASKET
0260 0007-2625-830 DICHTRING 1,000 PC 2
GASKET
0270 0007-2080-750 DICHTRING 1,000 PC 2
GASKET
LOCK RING
0290 0019-6335-400 GEWINDESTIFT 2,000 PC 2
THREADED PIN
0300 0007-2940-750 DICHTRING 1,000 PC 2
GASKET
0310 0007-2023-750 DICHTRING 2,000 PC 2
GASKET
LOCK RING
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 54
no.
SPINDLE SCREW
0360 0007-1941-750 DICHTRING 1,000 PC 2
GASKET
0990 0024-6180-000 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 56
no.
0024-0070-000 SCHILD 1,000 PC 2
PLATE
PARTS CATALOG

MATERIAL-NO. : 9987-0258-583 Page: 57
no.
0024-3531-010 KLEBESCHILD 1,000 PC 2
ADHESIVE PLATE
INSTALLATION, OPERATION AND MAINTENANCE
INSTRUCTION MANUAL FOR INDUCTION MOTORS ENGLISH
INSTRUCCIONES PARA LA INSTALACIÓN Y

MANTENIMIENTO DE MOTORES ELÉCTRICOS ESPAÑOL
BETRIEBS - UND WARTUNGSANLEITUNGEN FÜR

ELEKTROMOTOREN DEUTSCH
INSTRUCTIONS POUR INSTALLATION ET

MANUTENTION DE MOTEURS ÉLECTRIQUES FRANÇAIS
ISTRUZIONI D’USO E MANUTENZIONE

PER MOTORI ELETTRICI ITALIANO
INSTALLATIONS-OG VEDLIGEHOLDELSESVEJLEDNING
FOR ELEKTRISKE MOTORER DANSK
INSTALLATIONS- OCH UNDERHÅLLSINSTRUKTIONER

FÖR ELEKTRISKA MOTORER SVENSKA
ИНСТРУКЦИЯ ПО УСТАНОВКЕ И
ТЕХОБСЛУЖИВАНИЮ ЭЛЕКТРОМОТОРОВ PYCCKNÑ
INSTRUKCJA INSTALACJI, OBSŁUGI I EKSPLOATACJI

SILNIKÓW INDUKCYJNYCH POLSKI
MANUAL DE INSTALAÇÃO, OPERAÇÃO E MANUTENÇÃO

PARA MOTORES DE INDUÇÃO TRIFÁSICOS PORTUGUÊS
OIKOSULKUMOOTTORIEN ASENNUS-,
KÄYTTÖ- JA HUOLTO-OHJEET FINNISH
ENGLISH
INSTALLATION, OPERATION AND MAINTENANCE
INSTRUCTION MANUAL FOR INDUCTION MOTORS
04 - 15
ESPAÑOL
INSTRUCCIONES PARA LA INSTALACIÓN Y
MANTENIMIENTO DE MOTORES ELÉCTRICOS
16 - 28
ITALIANO FRANÇAIS DEUTSCH

BETRIEBS - UND WARTUNGSANLEITUNGEN FÜR
ELEKTROMOTOREN
29 - 41
INSTRUCTIONS POUR INSTALLATION ET MANUTENTION DE

MOTEURS ÉLECTRIQUES
42 - 54
ISTRUZIONI D’USO E MANUTENZIONE PER MOTORI

ELETTRICI
55 - 66
INSTALLATIONS-OG VEDLIGEHOLDELSESVEJLEDNING FOR
DANSK
ELEKTRISKE MOTORER
67 - 78
SVENSKA
INSTALLATIONS- OCH UNDERHÅLLSINSTRUKTIONER
FÖR ELEKTRISKA MOTORER
79 - 90
PYCCKNÑ
ИНСТРУКЦИЯ ПО УСТАНОВКЕ И ТЕХОБСЛУЖИВАНИЮ
ЭЛЕКТРОМОТОРОВ
91 - 104
INSTRUKCJA INSTALACJI, OBSŁUGI I EKSPLOATACJI

POLSKI
SILNIKÓW INDUKCYJNYCH
105 - 117
FINNISH PORTUGUÊS
MANUAL DE INSTALAÇÃO, OPERAÇÃO E MANUTENÇÃO

PARA MOTORES DE INDUÇÃO TRIFÁSICOS
118 - 130
OIKOSULKUMOOTTORIEN ASENNUS-, KÄYTTÖ- JA

HUOLTO-OHJEET
131 - 142

ENGLISH
INDEX
1. RECEIVING INSPECTION
2.HANDLING AND TRANSPORTATION
3. STORAGE
4. INSTALLATION
4.1 - Safety
4.2 - Operating Conditions
4.3 - Foundation
4.4 - Drain Holes
4.5 – Balance
4.6 – Alignment
4.7 - Couplings
4.8 – Electrical Connection
4.9 - Starting Methods
4.10 – Protection Device
4.11 - Start-Up
5 - MAINTENANCE
5.1 - Lubrication
5.1.1 - Machines without Grease Nipples
5.1.2 - Machines Fitted with Grease Fittings
5.1.3 - Compatibility of MOBIL Polirex EM grease with other types of grease
5.2 – Assembly and Disassembly
6 - SPARE PARTS
7 - VARIABLE FREQUENCY DRIVE MOTORS
7.1 - Standard Motors
7.2 - Inverter Duty Motors
7.3 – Bearing insulation
8 - ADDITIONAL INSTRUCTIONS
8.1 – Smoke Extraction Motors
8.2 – Hazardous Area Motors
8.2.1 General
8.2.2 Installation
8.2.3 Checking and Maintenance
8.2.4 Explosion Proof Motor Repairs
9. WARRANTY TERMS

This manual is intended to supply important topics that must be followed during
transportation, installation, operation and maintenance of WEG motors.
Therefore, we recommend reading carefully this manual before installing and
operating the motor.
To ensure physical integrity to the operation and material protection, all
ENGLISH
information included in this Manual must be strictly followed.
1. RECEIVING INSPECTION: This locking device must be

used on any further motor
When receiving the motor and anything has
transportation, even when this
been noticed, notify immediately the carrier,
means to uncouple the motor
the insurance company and WEG.
from the driven machine.
Failure in giving notice to the carrier, to the
insurance company and to WEG may result
in loosing product warranty. 3. STORAGE
If motors are not immediately installed, they
Do not remove the existing protecting must be stored in dry areas, free of dust,
grease from the shaft end, nor the stoppers vibrations, gases, corrosive smokes, under
or plugs that close the terminal box holes, constant temperature and in normal position
if any. These protection items must be kept free from other materials.
in place until the final installation has been
concluded. Motor storage temperature must remain
After being removed from the package, a between 5ºC to 60ºC, with relative humidity
complete visual inspection on the motor not exceeding 50%.
should be made:
If motors are stored for more than two years,
 Check if any damage has occurred during bearings must be replaced or the lubrication
transportation. grease must be totally removed after
 Check nameplate data. cleaning.
 Rotate the shaft by hand to make sure it is
turning freely. Single-phase motors when kept in stock for
 Make sure the motor was not exposed 2 years or more must have their capacitors
to excessive dirt and moisture during replaced (if any).
transportation and storage.
2. HANDLING AND WEG recommends to rotate the shaft (by
hands) at least once a month, and to measure
TRANSPORTATION
the insulation resistance before installing it, if
Motors must not be lifted by motors are stored for more than 6 months or
the shaft, but by the eyebolts
when subject to high humidity areas.
specific for such purpose.
If motor is fitted with space heaters, it is
recommended to switch them on during
Lifting devices, when supplied, are designed storage period if the relative humidity exceeds
only to support the motor. If the motor has 50%.
two lifting devices, then a double chain must If motor remains in stock for a long period
be used to lift it. without having the space heaters switched-
Lifting and lowering must be done gently on or when installed but not in operation,
without any shocks, to avoid bearing moisture/water inside the motor may
damage. condense. On these cases, water must be
drained by removing the threaded drain
During transportation, motors plugs. When drainage is done, switch-on the
fitted with roller or angular space heaters and make sure the motor is
contact bearings are protected completely dry, then reinstall the drain plugs
against bearing damages with a to ensure proper Degree of Protection (see
shaft locking device. figure 1).

The space heaters should NEVER be Where:
energized while motor is running. R(25°C) = insulation resistance related to
25ºC ambient temperature
K = constant value 234.5 for copper
Ta = ambient temperature where the
resistance was measured
R(Ta) = resistance value measured in
ambient temperature Ta
4. INSTALLATION
4.1 – Safety.
Drain plug position
All personnel involved with electrical installa-
tions, either handling, lifting, operation, start
up, maintenance or repair must be well in-
Figure 1 formed and updated concerning safety stan-
Drain plugs
Insulation Resistance Checking dards and principles that govern the work
and carefully follow them.
Disconnect motor from power supply
before making any insulation resistance For practical reasons, it is not possible to
measurement. include in this Manual detailed information
To avoid electric discharge risks, discharge that covers all constructive variables, nor
the terminals right after performing the covering all possible assembly, operation or
measurement. maintenance alternatives.
For this reason, the present Manual only
Measure the insulation resistance before includes required information that allows
operating the motor and/or when there is any qualified and trained personnel to carry out
sign of moisture in the winding. the work.
The resistance measured at 25ºC must be: If you still have further questions about it,
especially in reference to specific product
Ri ≥(20 x U) / (1000 + 2P) [MΩ] information, WEG is willing to provide such
(measured with a MEGGER at 500 V d.c.) information via its network of authorized ser-
where U = voltage (V); P = power (kW). vice agents and/or distributors.
In order to allow WEG to provide prompt ser-
If the insulation resistance detected is less
vice, within technical standards, the motor
than 2 M W, the winding must be dried
serial number that is available on the identifi-
according to the following procedure:
cation nameplate should be supplied.
Dismantle the motor and warm up the
Use always appropriate tools for installation
frame and stator in an oven at a minimum
and removal.
temperature of 80ºC increasing 5ºC every
hour until reaching 105ºC, remaining under Make sure that electric motors
this temperature for at least one hour. are switched off before starting
Check if the stator insulation resistance any maintenance service.
remains constant within accepted values.

If not, stator must be reimpregnated. If All rotating parts such as pulleys, couplings,
necessary, replace bearings and seals. outside fans, shaft, etc. must be protected
against accidental contacts.
Notes: Motors must be protected against unexpec-
1 - Measure the insulation resistance in ted starts.
ambient temperature. If different than 25ºC When performing any maintenance service,
it should be corrected using the following disconnect the motor from the power supply.
formula: Make sure all accessories have been swi-
R(25°C) = [( K+25 ) / ( K + Ta )] . R(Ta) tched off and disconnected.
In order to prevent from penetrating dust

and/or water inside the terminal box, cable with moisture, dirt and/or corrosive materials
glands or threaded pipe in the lead passage either in enclosed or open environments.
holes must be installed. It must be equal or
higher IP rating than the motor. 4.3 - Foundation
Lead connection insulation
ENGLISH
Motors provided with feet must be installed
inside the terminal box must be on solid foundations to avoid excessive
done with an insulating material vibrations.
compatible with motor thermal All motors must be fully fixed and aligned.
class which is shown on the The purchaser is fully responsible for the
motor nameplate. foundation.
Metal parts must be painted to avoid
If installation and safety instructions are not
corrosion.
followed accordingly, warranty may be void.
The foundation must be uniform and
4.2 - Operating Conditions
sufficiently strong to support any shock. It
must be designed in such a way to stop any
In general electric motors are designed for
vibration originated from resonance.
operation up to an altitude of 1000m above
sea level for an ambient temperature ranging
Note: Considering that rotation direction is
from -20ºC to 40ºC. Any variation is stated
important for correct operation, then check
on the nameplate.
it carefully before connecting motor to the
The recommended installation distance be-
load.
tween air inlet from the motor and the wall
should be at least ¼ of the air inlet diameter. 4.4 - Drain Holes
A person should have enough room to carry
out cleaning services. Make sure drains are placed at the lower motor
Machines that are cooled with ambient air, position when the mounting configuration
air inlet screens must be cleaned at regular differs from that specified on the motor
intervals so as to ensure free air circulation. purchase order.
Warm air can not return to the motor. 4.5 – Balance
- For vertically mounted motors with air inlet
on top, the air opening must be protected by
When special balance is
a proper cover so as to avoid dropping of
required, contact the factory.
foreign materials on the motors.
- Considering that direct sun heat causes
increase in temperature, externally installed All motors are dynamically balanced at the
motors should be always protected against factory with half key.
weathering.
Transmission elements such as pulleys, cou-
Compare the current, voltage, plings etc must be dynamically balanced with
frequency, speed, output and half key before installation.
other values required by the
application with motor nameplate Use always appropriate tools for installation
information. and removal.
ODP MOTORS – Open motors (IP21, IP23) 4.6 – Alignment
are machines designed for operation in clean, Align the shaft ends and use
dry areas, with enough air circulation for flexible coupling, whenever
proper cooling. These motors should never possible.
be used in areas with flammable materials.
Open motors may cause sparks and release Make sure that the motor mounting devices
cast particles under any eventual insulation do not allow modifications on the alignment
failure (short-circuit). and further damages to the bearings.
TEFC MOTORS – Totally enclosed motors When assembling a coupling, make sure to
are machines suitable to operate in areas use suitable equipment and tools to protect

the bearings. duly trained as well as laser equipment to
Suitable assembly of coupling: make motor and driven machine alignment/
Specially in cases of direct couplings, motor leveling.
shaft must be aligned axially and radially with
the driven machine shaft. Expansion effect of the components may
change the alignment/leveling conditions
Incorrect alignment can lead to bearing during motor operation.
damage, vibrations or even cause shaft
rupture. 4.7 - Couplings
Correct alignment can be ensured with the
use of dial gauges, as shown in figures 4.6.1, When using pulley and belt/chain drive
(coupling), follow the instruction given
4.6.2 and 4.6.3.
below:
If considering a complete shaft rotation,
 Remove shaft-locking device (if any) before
misalignment should not exceed 0.05 mm.
installing the motor.
 Belts must be tighten just enough to avoid
slippage when running, according to the
specifications stated on the belt supplier
recommendation.
 To make the installation of the pulley on the
shaft easier, it is recommended to heat up
the pulley at 80°C and have it mounted at
Fig. 4.6.1 - Axial reading (parallelism) hot, using suitable tools.
 To avoid bearing and shaft end damage,
assembly and disassembly the pulleys must
be made with suitable tools.
 While assembly and disassembly a pulley,
never make pressure or knocks on the
bearings.
 Always use flexible couplings; rigid couplings
require special bearing arrangement as well
as axial and radial alignment of the shafts.
WARNING:
Fig. 4.6.2 – Radial reading (concentricity) Excessive belt/chain tension will
damage the bearings and lead to a
probable shaft rupture.
Couplings used must be suitable to

withstand radial and axial vibrations during
operation. Special care must be taken to
avoid that the allowable load and speed
limit values showing in the catalogs are not
exceeded.
4.8 – Electrical Connection
Fig. 4.6.3 – Axial and radial reading combined Make sure the motor is connected to the
correct power supply.
The axial alignment (“E” dimension) between
Cable gauges and protection devices must
the couplings must be 3mm minimum to
be designed based on motor rated current.
compensate the thermal shaft dilation.
If required, WEG can offer its personnel

Voltage may be connected at motor Rotation direction is clockwise when motor is
~ standstill inside the terminal box for
heating elements or direct winding
viewed from Drive Endshield side and if the
phases are connected according to sequence
heating. L1, L2, L3. This phase sequence and power
system must be positive.
ENGLISH
The capacitor on single-phase
motors can retain a charge which
~ appears across the motor terminals,
To change the rotation direction, reverse two
of the connecting leads.
even when the motor has reached
standstill condition. So, avoid Note: For single-phase motor connections,
touching them at such condition. please check the motor nameplate.
A wrong connection can The connection to the power
burn out the motor. supply must be done by qualified
personnel and with full attention
to assure safe and permanent
Voltage and connection are indicated on the
connection. after connecting the
motor nameplate according to IEC 60034-1.
motor, check for any strange
The acceptable voltage variation is ±5% and
body inside the terminal box. the
the acceptable frequency variation is ±2%,
cable inlets not in use must be
according Zone A - IEC
closed.
60034-1 Standard.
Note: For rated voltage range (multivoltage), Before energizing the terminals,
check if the grounding is made
the acceptable variation is ± 5%.
according to the applicable
standards. this is essential to
4.9 - Starting Methods
avoid accidents.
The motor is rather started through direct
starting. In case this is not possible, use 4.10 – Protection Device
compatible start methods to the motor load
and voltage. When the motor is supplied with protective
When applying reduced voltage starting me- or monitor temperature device such
thod, remember that the starting torque will as thermostats, thermistors, thermal
also reduce. protector etc, connect their terminals to the
corresponding devices on the control panel.
Possible motor Connections: If this procedure is not followed accordingly,
warranty will be void.
 3 leads single voltage and 9 leads dual vol-
Do not change protection devices settings as
tage motors can be started as follows:
they may not operate.
- Full Voltage Direct online
- Auto-Transformer starting Protection Device Diagram
- Electronic Soft-Starting
- VFD Starting – subject to verification and
application analysis.
- Series - Parallel starting (only for 9 leads) Overtemperature
Protected motor
 6 leads single and dual voltage motors with thermostats
and 12 leads dual voltage motors can be
connected as follows: L1 L2 L3
- Full Voltage Direct online Stop switch
- WYE/DELTA starting
- Auto-Transformer starting RATED CURRENT
VOLTAGE(V) (A)
- Electronic Soft-Starting 3x 110-120 3.00
220-240 1.50
- VFD Starting – subject to verification and 440-480 0.75
550-600 0.60
application analysis. THERMOSTATS LEADS
- Series - Parallel starting (only for 12 leads)

 Check bearing condition and pay attention
to: Any excessive noise, vibration, bearing
Overtemperature temperature and grease condition.
Protected motor  When a change, under normal conditions
with thermistors is detected, check the motor and replace
required parts.
L1 L2 L3
do not reuse damaged or worn
parts. replace them by new ones
supplied by the factory.
3x Periodical inspection depends on motor type

RELEASE DEVICE and on application conditions.
THERMISTORS LEADS
5.1 – Lubrication.
4.11 - Start-Up follow regreasing intervals. this
is fundamental for proper motor
If the motor is running bare operation.
shaft, the key must be fastened
or removed before starting. 5.1.1 - Machines without Grease Nipples
Motors up to frame size 200 are normally
a) The motor must start and operate smoothly. fitted without grease fittings. In these
In case this does not occur, turn it off and cases the regreasing shall be done during
check all connections and the mounting preventive maintenance service paying
before starting it again. attention to the following aspects:
 Take motor apart carefully.
b) In case there is excessive vibration, check  Take all the grease out.
if the fixing screws are correctly fastened.  Wash the bearing with kerosene or diesel.
Check also if the vibration comes from a  Dry the bearings.
neighbor machine. Periodical vibration check  Regrease the bearing immediately.
must be done.
5.1.2 – Motors Fitted with Grease Fitting
c) Run the motor under rated load for a short It is strongly recommended to grease the
period of time and compare if the running machine while running. This allows the
current is in accordance to the nameplate grease renewal in the bearing housing.
current. When this is not possible due to rotating
parts by the grease device (pulleys, bushing,
5 - MAINTENANCE etc) that offer some risk to physical integrity
of the operator, proceed as follows:
Any service in electric machines should only  Turn off the motor
be carried out when it is completely stopped  Clean the area near the grease nipple.
and all phases disconnected from the power  Put approximately half of the total grease
supply. and run the motor for 1 minute at full speed.
Then turn off the motor and pump in the rest
of the grease.
WARNING:
 The injection of all the grease with the
safety check list
motor in standstill can make the grease
penetrate into the motor, through the bearing
General Inspection housing inner seal.
 Check motor periodically. Inspections intervals depend on motor type
 Keep motor clean and ensure free air flow. and on application conditions.
 Check seals and replace them, if required.
use only manual grease gun for
 Check connections as well as supporting
lubrication.
screws.
10
TABLE 1 - BALL BEARINGS - Series 62/63
Relubrication intervals (running hours – horizontal position)
62 Series
II pole IV pole VI pole VIII pole X pole XII pole Grease
Bearing
60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz (g)
ENGLISH
6209 18400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 9
6211 14200 16500 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 11
6212 12100 14400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
63 Series
II pole IV pole VI pole VIII pole X pole XII pole Grease
Bearing
6309 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
6311 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
6312 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
6314 3600 4500 9700 11600 14200 16400 17300 19700 19700 20000 20000 20000 27
6316 - - 8500 10400 12800 14900 15900 18700 18700 20000 20000 20000 34
6319 - - 7000 9000 11000 13000 14000 17400 17400 18600 18600 20000 45
6322 - - 5100 7200 9200 10800 11800 15100 15100 15500 15500 19300 60
TABLE 2 - ROLLER BEARINGS - NU 3 Series

Relubrication intervals (running hours – horizontal position)
II pole IV pole VI pole VIII pole X pole XII Pole Grease
Bearing
NU 309 9800 13300 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
NU 311 6400 9200 19100 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
NU 312 5100 7600 17200 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
NU 314 1600 2500 7100 8900 11000 13100 15100 16900 16900 19300 19300 20000 27
NU 316 - - 6000 7600 9500 11600 13800 15500 15500 17800 17800 20000 34
NU 319 - - 4700 6000 7600 9800 12200 13700 13700 15700 15700 20000 45
NU 322 - - 3300 4400 5900 7800 10700 11500 11500 13400 13400 17300 60
NU 324 - - 2400 3500 5000 6600 10000 10200 10200 12100 12100 15000 72
Notes:
The tables above are specifically intended of grease and relubrication intervals is given
for relubrification with MOBIL Polyrex EM on an nameplate attached to the motor.
grease and bearing absolute operating
temperature of: We recommended to use ball
 70ºC (158ºF) for 160 to 200 frame size bearings for motors directly
motors coupled to the load
 85ºC (185ºF) for 225 to 355 frame size
motors
WARNING:
For every 15ºC (59ºF) above these limits,
Excess of grease can cause
relubrification intervals must be reduced by
bearing overheating resulting
half. Shielded bearing (ZZ) are lubricated for
in complete damage.
bearing life as long are they operate under
normal conditions and temperature of 70ºC 5.1.3 - Compatibility of MOBIL Polirex EM
(158ºF). grease with other types of grease:
 Relubrication periods given above are for
those cases applying MOBIL Polyrex ® EM Containing polyurea thickener and mineral oil,
grease. the MOBIL Polyrex EM grease is compatible
 When motors are used on the vertical with other types of grease that contain:
position, their relubrication intervals are
reduced by half if compared to horizontal  Lithium base or complex of lithium or
position motors. polyurea and highly refined mineral oil.
 On applications with high or low  Inhibitor additive against corrosion, rust
temperatures, speed variation etc., the type and anti-oxidant additive.
11
Note: Before installing a new bearing it is required
 Although MOBIL Polyrex EM is compatible to check the shaft fitting for any sharp edge
with the types of grease given above, we do or strike signals.
not recommend mixing it with any other types
of grease. For bearing assembly, warm their inner parts
 If you intend to use a type of grease with suitable equipment – inductive process
different than those recommended above, – or use suitable tools.
first contact WEG.
Before using standard motors 6 - SPARE PARTS
in specific areas or on special
applications, first contact the When ordering spare parts, please specify
grease manufacturer or weg the full type designation and product code
5.2 Assembly and Disassembly as stated on the motor nameplate. Please
also inform the motor serial number stated
Disassembly and assembly must be done by on the nameplate.
qualified personnel using only suitable tools
and appropriate methods. 7 - VARIABLE FREQUENCY DRIVE
The bearing extractor grips must be applied MOTORS
over the side face of the inner ring to be
disassembled or over an adjacent part. 7.1 - Standard Motors Line
It is essential to assemble bearings under
Motors with voltages up to 575V and fed by
clean conditions to ensure good operation
VFD do not require filters if follow the criteria
and to avoid damages. New bearings shall
below:
only be taken out from their packages when
mounting them.
(*) Informed by the drive manufacturer. * Other frame sizes, under request.
Note:
7.2 - Inverter Duty Motors Line
1) Nameplate showing voltage 380-
415V/660-690V – 50Hz and 440-480 – 60Hz, Motors with voltages above 575V and equal
and fed by VFD on voltage 660-690V – 50Hz or below 690V and fed by VFD do not require
or 480V – 60Hz require filters. filters when following the criteria below:
TECHNICAL CRITERIA FOR VFD APPLICATION

Insulation dV/dt Rise Time(*)
Rated Voltage Voltage Spikes MTBP(*)
System inverter inverter
motor terminals Minimum Time
terminals terminals
(maximum) Between Pulse
(maximum) (minimum)
Reinforced
575V Vrated 690V 2140V 7800 V/ s 0,1 s 6 s
Insulation
(*) Informed by the drive manufacturer.  Check power supply voltage of the forced
cooling set.
12
7.3– Bearing insulation: 8.2 Hazardous area motors
Inverter Duty Motors Line in frame sizes 8.2.1 General
315S/M and 355M/L* are supplied with
Besides the recommendations given above,
ground system between the shaft and frame
these recommendations must be also
ENGLISH
on D.E. Also, on request can be supplied
followed.
with insulated bearings.
Hazardous area motors are manufactured
For other lines, in frame sizes 315S/M and according to specific standards for such
355M/L* when used with VFD’s, it is required environments.
ground system between the shaft and frame Motors supplied for hazardous area (classified
or insulated bearings. areas) must be installed in areas that comply
with those specified on the motor nameplate.
(*) Other frame sizes, under request.
Notes:
8 - ADDITIONAL INSTRUCTIONS - Motors of Zone 1 are also suitable for Zone 2.
8.1 - Smoke extraction motors - Motors of the group IIB are suitable also for
the group IIA.
Due to their application, Smoke Extraction - Motors of the group II or IIC are suitable also
Motors require the following additional for the groups IIA and IIB.
operating instructions: - Motors of a given class of temperature are
suitable also for combustible environments of
- Ensure that the motor temperature class,
a greater class of temperature (example, T4
indicated on the identification nameplate,
motors are suitable for environments of class
matches with the maximum operating
T3, T2, T1).
temperature.
- Install non-ventilated motors right on the 8.2.2 Installation
air flow of the cooling fan. Self-ventilated
motors can be installed out of the air flow. A complete installation must follow procedures
- Bearings of Smoke Extraction Motors given by local legislation in effect.
must be relubricated with Krytox GPL 226 The installation of hazardous
grease (special grease for Smoke Extraction area motors must be carried out
Motors). The relubrication intervals are by skilled people.
5 times higher (limiting on 20.000 hours)
as those applied to MOBIL Polyrex® EM The specification of the motor
grease, specified on table 1 and 2. After installation site is for customer’s
20.000 accumulated running hours the responsibility, who will also
bearings must be replace. determine the environment
- The amount of grease for Krytox GPL characteristics.
226 is the double of the values indicated to
MOBIL Polyrex® EM on the table 1 and 2. When cable entrance is made by a cable
- Provide a control system to switch-off gland, this must be suitable to the unit and
motor thermal protection devices during to the type of cable; the cable gland has to
Smoke Extract Duty. be assembled, completely screwed in order
- If the motor at normal condition (40°C to get the necessary pressure on the sealing
ambient) is driven by Inverter (VFD), at rings, so as to:
Smoke Extraction Duty it must be connected - Avoid transmission of mechanical vibrations
direct on line. to the motor terminals.
- The lifetime of the winding is 40.000 hours. - Guarantee mechanical protection “IP” to the
Change the whole motor when the winding terminal box.
has been use for this time.
- Every time a motor is used for Smoke 8.2.3 Checking and maintenance
Extract Duty, this motor must be replaced Maintenance must be carried out by repair
as it should be used only once under such shops duly authorized and accredited by
condition. WEG.
13
Repair shops and people without WEG’s they can be oiled by means of a thin coat of
authorization who will perform any service silicon grease.
on hazardous area motors will be fully  Check if all components are free of edges,
responsible for such service as well as for any knocks or dirt.
consequential damage.  Make sure all parts are in perfect
conditions.
When performing maintenance, installation or  Lubricate the surfaces of the endshield
relubrication, follow these instructions: fittings with protective oil to make the
 Electric connections must be correctly assembly easier.
locked to avoid resistance-increases, with  Use only rubber hammer to fit the parts.
consequent contact overheating.  Check correct bolt fastening.
 Insulation air-distance and surface-  Use clearance calibrator for correct
distance between conductors, required by connection Terminal box fitting (less than
the Standards, must be respected. 0.05mm).
 All screws, used to assemble motor
parts and terminal box, must be completely 8.2.4 Explosion proof motor repairs
screwed.
Repair of parts, directly involved in the
 Seals and components replacement for
protection against risk of an explosion, must
cable entrance would be made using spare
be done without any modification to the
parts, supplied from the manufacturer, in order
original motor design.
to guarantee the original type of protection.
 Explosion Proof motors joint surfaces have After the repair, these parts must be
not to be machined and it is not allowed to submitted to a check and test control and
insert, between them, any kind of seals, not when concluded, the repair shop must issue
foreseen or supplied by the manufacturer. a statement about all operations performed
Joint surfaces have just to be cleaned and, in on a specific motor.
order to avoid corrosion or water penetration;
9. WARRANTY TERMS
WEG warrants its products against defects in workmanship and materials for eighteen (18)
months from the invoice date issued by the factory, authorized distributor or agent limited to
twenty four (24) months from manufacturing date independent of installation date as long as
the following items are fulfilled accordingly:
- Proper transportation, handling and storage;
- Correct installation based on the specified ambient environmental conditions;
- Operation under motor capacity limits;
- Observation of the periodical maintenance services;
- Repair and/or replacement effected only by personnel duly authorized in writing by WEG;
- The failed product be available to the supplier and/or repair shop for a required period to
detect the cause of the failure and corresponding repair;
- Immediate notice by the purchaser about failures occurred and that these are accepted by
WEG as manufacturing defects.
This warranty does not include disassembly services at the purchaser facilities, transportation
costs with product, tickets, accommodation and meals for technical personnel when
requested by the customer.
The warranty service will be only carried out at WEG Authorized Repair Shops or at WEG’s
facilities.
Components whose useful life, under normal use, is shorter than the warranty period are not
covered by these warranty terms.
The repair and/or replacement of parts or components, when affected by WEG and/or any
WEG Authorized Repair Shop, will not give warranty extension.
This constitutes WEG’s only warranty in connection with this sale and the company will have
no obligation or liability whatsoever to people, third parties, other equipment or installations,
including without limitation, any claims for consequential damages or labor costs.
14
DECLARATION OF CONFORMITY
Manufacturer’s name and WEG EQUIPAMENTOS ELÉTRICOS S.A. - MOTORES
Address: Av. Prefeito Waldemar Grubba, 3000
89256-900 Jaraguá do Sul –SC - Brazil
ENGLISH
We declare under sole responsibility that the products:
* Single- or three-phase induction motors (cast iron frame)
IEC frame 63 up to 355M/L
* Single- or three-phase induction motors (aluminum frame)
IEC frame 63 up to 132M
* Single- or three-phase induction motors (cast iron frame)
NEMA frames 143 up to 587 and 56
to which this declaration relates are in conformity with the following standards:
* IEC 60034-1/2 / 2A/5/6/7/8/9/11/12/14
* IEC 60072 - 1/2
European Standard German Standard VDE-Classification.
EN 55014-1:1993+A1:1997+A2:1999 DIN EN 55014-1:1999-10 VDE 0875 Part 14-1:1999-
10
EN 61000-6-2:1999 DIN EN 61000-6-2:2000-03 VDE 0839 Part 6-2:2000-03
EN 61000-3-2:1995+Corr.:1997+A1:1998 + A2:1998 DIN EN 61000-3-2:1998-10
VDE 0838 Part 2:1998-10
EN 61000-3-2:1995/A14:2000 DIN EN 61000-3-2/A14:2001-01 VDE 0838 Part 2/A14:2001-
01
Designation:
The motors are provided with a CE mark, since January 1st, 1996.
By design, the motors, considered as components, comply with the requirements of following
European Directives:
Low Voltage Directive 73/23/EEC from February 19th, 1973, amended by Directive 93/68/EEC
of July 22nd, 1993,
EMC Directive 89/336/EEC from May 3rd, 1989, including amendments, regarding to the
intrinsic characteristics to emission and immunity levels of Electromagnetic Compatibility
(EMC),
Machinery Directive 89/392/EEC from June 14th, 1989, amended by 91/368/EEC, 93/44/
EEC and 93/68/EEC, in accordance with article 4(2) and annex IIB, Paragraph B, provided
the motors are installed according to our Installation and Maintenance Instructions. The
above mentioned directives were combined, without deviation, in one document as Directive
98/37/EC from June 22nd, 1998. The Directive 98/37/EC cancels and replaces these old
Directives.
Certificate of Incorporation:
The above products cannot be put into service until the machinery into which they are
incorporated has been declared to be in conformity with the Machinery Directive (89/392/
EEC).
The Safety Notices in the product documents and the applicable installation specification (for
instance EN 60204) must be followed.
Jaraguá do Sul, June 16th, 2006
Siegfried Kreutzfeld
Engineering Director
15
WEG EXPORTADORA S.A.
Av. Pref Waldemar Grubba, 3000
89256-900 Jaraguá do Sul, SC – Brazil
phone: +55 47 3372-4002 - fax: +55 47 3372-4060
www.weg.net
FOR FUTHER INFORMATION PLEASE CONTACT YOUR NEAREST SALES OFFICE
6 Pumps
Pumpen
6.1 Gear Pump

Zahnradpumpe
Type KF 63
6.2 Diaphragm Pump Unit
Type P1

Operating instructions
BKF0004EN
Transfer Gear Pumps KF 4...80
BKF0004EN_D0024710002_04
Englisch
2010-06-09
Table of Content
1 General points 5
1.1 About the documentation 5

1.2 Manufacturer´s address 5
1.3 Intended use 5
2 Safety 7
2.1 Safety instructions and symbols 7

2.2 Staff qualification and training 7
2.3 General safety instructions 7
2.4 Hazard statements 8
3 Device description 11
3.1 General points 11

3.2 Basic construction 12
3.2.1 KF 4...80 R/L/B 12
3.2.2 KF 4...80 R/L - D 13
3.2.3 KF 4...25 U 14
3.2.4 KF 32...80 U 15
3.3 Types of seals 16
3.4 Type key 17
3.5 Important special numbers 18
4 Technical data 19
4.1 General characteristics 19

4.2 Overview of nominal sizes 20
4.3 Recommended speed 20
4.4 Overview materials 21
4.5 Overview of operating pressure and fluid tempera- 22
ture
4.6 Dimensions 23
5 Transport and storage 24
5.1 Transport damage 24

5.2 Transport 24
5.3 Corrosion protection 26
6 Installation 27

6.2 Noise reduction 27
6.3 Definition of the direction of rotation and pumping 27
flow
6.3.1 KF 4...80 28
6.3.2 KF 4...25 U 29
6.3.3 KF 32...80 U 29
6.4 Change of the direction of rotation 30
6.5 Design of suction and pressure line 32
6.5.1 Suction line 32
6.5.2 Pressure line 34
6.6 Mounting the clutch 36
6.7 Mechanical installation 39
6.8 Assembly with further components and devices 41
6.9 Electrical connection 41
7 Operation start-up 43
7.1 Preparation 43
7.2 Pumps with liquid seal (quenching connection) 44
7.2.1 Description 44
7.2.2 Versions 45
7.3 Setting the pressure relief valve 46
7.4 Further operation start-up 47
8 Removal 48

8.2 Disassembling the pump 48
9 Maintenance 50

9.2 Unusual noises 52
9.3 Cleaning 52
9.4 Static seals 52
9.5 Confining fluid level 52
9.6 Rotary shaft lip seals 52
9.7 Mechanical seal 53
9.8 Clutch 53
9.9 Screw joints 53
9.10 Damage 53
9.11 Surface temperature 54
9.12 Bearings, gear, wheel chamber housing 54
10 Repairs 55

10.2 Troubleshooting 55
10.3 Elimination of damage 55
10.4 Return 55
10.5 Detecting and eliminating problems 56
1 General points
1.1 About the documentation
These operating instructions describe the installation, operation and mainte-

nance of the transfer gear pumps KF 4...80, also referred to below as the
device.
The device is manufactured in different versions. Information about the ver-
sion concerned in the individual case can be found on the device's type plate.
The structure of the type designation and a more detailed description of the
individual series and nominal sizes can be found in the chapter "Technical
data" and in the chapter "Device description".
If you have any questions about this operating manual, please contact the
manufacturer.
1.2 Manufacturer´s address
Kracht GmbH
Gewerbestraße 20
DE 58791 Werdohl
phone: +49 (0) 23 92 / 935-0
fax: +49 (0) 23 92 / 935-209
email: info@kracht.eu
web: www.kracht.eu
1.3 Intended use
The device is a pump for continuous delivery of liquids. The various seal var-
iants and materials enable use with different media.
The device has been designed for operation with fluids. Dry operation is not
permitted. The medium must guarantee a minimum lubrication.
The medium must not contain any abrasive constituents.
Petrols, solvents, etc. are not permissible.
Use in explosive areas is not permissible.
It must be guaranteed that the medium is compatible with the materials used
in the device (see "Overview materials" in chapter "Technical data").
The maximum permissible operating data listed in the "Technical data" chap-
ter must always be observed.
BKF0004EN_D0024710002_04 2010-06-09 5
Deviations from the above-mentioned data and operating conditions require

express approval by the manufacturer and/or are specified on the type plate.
Type plates or other references on the device must not be removed nor made
illegible or irrecognisable.
In cases of noncompliance, all warranty claims and manufacturer responsi-
bility shall be void.
6 2010-06-09 BKF0004EN_D0024710002_04
2 Safety
2.1 Safety instructions and symbols
The safety notices in these operating instructions are marked with caution
symbols.
Non-compliance can lead to hazards for people and the device.
In addition, the safety instructions are marked with signal words. They have
the meanings as explained below:
Caution: Identification of a low risk hazard, which could lead to minor or
medium bodily injury if not avoided.
Warning: Identification of a potential medium risk hazard, which would lead
to death or severe bodily injury if not avoided.
Danger: Identification of an immediate hazard, which would result in death
or severe bodily injury if not avoided.
Notice: Flagging of notices to prevent property damage.
Flagging of special user tips and other especially useful or important infor-
mation.
2.2 Staff qualification and training
The staff designated to install, operate and maintenance the device must be
properly qualified. This can be through training or specific instruction. Staff
must be familiar with the contents of this operating manual.
2.3 General safety instructions
The operational safety of the device delivered is only guaranteed when it is

used for the intended purpose (see chapter "General points").
The limit values given must never be exceeded (see chapter "Technical
data").
National regulations concerning accident prevention and health and safety
at work must be observed, as well as internal regulations laid down by the
operator, even if these are not specifically mentioned in this manual.
The operator must ensure that this operating manual is accessible to the
staff responsible at all times.
BKF0004EN_D0024710002_04 2010-06-09 7
2.4 Hazard statements
DANGER
Hazard caused by breakage or fluids spurting out
Positive displacement pumps must never deliver against "closed gate
valves" as the uncontrollable pressures developing in this case will entail
damages on the device and on upstream and/or downstream system ele-
ments.
For this reason, it is vital to use a pressure relief valve as close as possible
to the pump pressure connection or another type of pressure relief device.
It must be taken into consideration that the whole delivery must be dis-
charged via the pressure limiting device.
DANGER
Only connections and pipes approved for the pressure range to be expected
may be used.
The respective manufacturer's regulations must be heeded.
DANGER
Damaged pipes and hoses must be replaced immediately.
DANGER
Hazard caused by hazardous fluids
When operating the device with hazardous fluids, comply with the safety
datasheets and the regulations on handling these fluids.
Leaks of hazardous transport materials must be collected in such a manner
that no hazards arise for people and the environment.
Always comply with the existing national and international regulations ap-
plicable at the place of installation.
DANGER
Hazard caused by rotating parts
There is a risk of snagging or getting reeled in.
The user must protect rotating parts against unintentional contact.
Existing maintenance openings on the bellhousing must be closed.
Operation without protection device is not permissible.
8 2010-06-09 BKF0004EN_D0024710002_04
DANGER
Hazard caused by rotating parts and fluids spurting out
Render the connection lines pressureless and disconnect the motor from
mains for all work on the device and prior to its removal.
Likewise, premature restarting of the motor during work must be prevented.
DANGER
Danger posed by voltage
The special safety regulations shall be followed for any work on electrical
installations. This work may only be carried out by a qualified electrician.
DANGER
Hazard caused by falling and tipping loads
During transport, accidents can occur due to the size and weight of the
device.
Compliance with applicable industrial safety requirements is mandatory.
Wear suitable protective clothing.
Use only suitable means of conveyance and lifting tackle with sufficient
load-bearing capacity.
Attach lifting tackle only to suitable points.
Attach the lifting tackle in such a manner that it cannot slip.
The unit's centre of gravity must lie between the lifting tackle mounting
points on the unit.
Secure the unit so that toppling over and falling down is impossible.
Always avoid jerks, impacts and strong vibrations during transportation.
Never walk under suspended loads.
Never work under suspended loads.
WARNING
Hazard caused by shearing in case of rotating gears
Device must only be put in operation with its lines connected.
WARNING
Hazard caused by incorrect direction of rotation
An incorrect direction of rotation may result in serious damages to man and
machine.
Absolutely observe the correct direction of rotation when installing the pump
and connecting the motor electrically to guarantee safe operation.
BKF0004EN_D0024710002_04 2010-06-09 9
CAUTION
Hazard caused by hot surfaces
The user is to take measures against unintended contact at temperatures
above 60°C.
CAUTION
At operating temperature above 48 °C the device must be allowed to cool
down first. Danger of scalding.
10 2010-06-09 BKF0004EN_D0024710002_04
3 Device description
3.1 General points
KF series pumps are external gear pump types that work according to the
positive displacement principle.
When rotated, two gears being engaged with each other cause volume ex-
pansion by opening the tooth gaps in the pump inlet (suction side) so that the
medium can enter while a corresponding volume is being displaced in the
pump outlet (pressure side) through engagement of the teeth into the filled
tooth gap. Fluid transport takes place through entrainment in the tooth gaps
along the wall of the wheel chamber. The so-called geometric flow rate Vg is
being displaced per wheel rotation. A value that is stated in technical docu-
ments as rated volume Vgn to specify the pump size.
The actually delivered amount of liquid does not correspond with the theo-
retical value, it is being reduced through losses due to the necessary toler-
ances. The losses are less the lower the operating pressure and the higher
the viscosity.
Gear pumps are self-priming within wide limits. The displacement cycle de-
scribed initially takes place without exhibiting appreciable pressure build-up.
Only after setting external loads, for example, through delivery head, outlet
resistances, line elements, etc. the required working pressure will arise to
overcome these resistances.
As usual with so-called rigid pumps, i.e. non-axial play compensated pumps,
the lateral clearance between gear and front face has been set in such a way
that the maximum allowable operating pressure is managed in an adequate
and secure way.
The medium lubricates the pump's friction bearings. The pump's life will be
reduced if the medium should contain abrasive ingredients.
The shaft sealing pocket is connected to the pump's suction side. Therefore,
the max. permissible suction-side pressure is dependent on the type of seal.
Tab. 3.1: Functional principle external gear pumps
ps = Suction side
pd = Pressure side
BKF0004EN_D0024710002_04 2010-06-09 11
3.2 Basic construction
3.2.1 KF 4...80 R/L/B
Tab. 3.2: Basic construction KF 4...80
* Direction of rotation "B" (Right and left)

1. Cover 8. Retaining ring
2. O-Ring 9. Parallel key
3. Housing 10. Hexagonal screw
4. Driven shaft 11. Adapter sleeve
5. Driving shaft 12. Valve
6. Plain bearing bush 13. Adjusting washer
7. Rotary shaft lip seal 14. Retaining ring
See section "Types of seals" for further seal types.
12 2010-06-09 BKF0004EN_D0024710002_04
3.2.2 KF 4...80 R/L - D
Tab. 3.3: Basic construction KF 4...80 R/L - D
1. Valve cover 10. Set screw

2. O-Ring 11. Hexagonal nut
3. Housing 12. Retaining screw
4. Driven shaft 13. O-Ring
5. Driving shaft 14. Compression spring
6. Plain bearing bush 15. Valve cone
7. Retaining ring 16. Adapter sleeve
8. Rotary shaft lip seal 17. Hexagonal screw
9. Parallel key
BKF0004EN_D0024710002_04 2010-06-09 13
3.2.3 KF 4...25 U
Tab. 3.4: Basic construction KF 4...25 U
1. Valve housing 10. Roller bearing 19. Retaining ring

2. Gasket 11. Retaining ring 20. Parallel key
3. Adapter piece 12. Hexagonal screw 21. Cover
4. Plain bearing bush 13. Retaining ring 22. O-Ring
5. O-Ring 14. Valve washer 23. Rod
6. Driven shaft 15. Valve cone 24. Compression spring
7. Driving shaft 16. Socket head cap screw 25. Centering star
8. Plain bearing bush 17. Socket head cap screw 26. Piston
9. Housing 18. Rotary shaft lip seal
14 2010-06-09 BKF0004EN_D0024710002_04
3.2.4 KF 32...80 U
Tab. 3.5: Basic construction KF 32...80 U
* View without connection elbow

** View without universal device
1. Hexagonal screw 11. Compression spring 21. Plain bearing bush
2. Screw plug 12. Valve housing 22. Driving shaft
3. Gasket 13. O-Ring 23. Driven shaft
4. Socket head cap screw 14. Cover 24. O-Ring
5. Connection elbow 15. Parallel key 25. Cover
6. Gasket 16. Retaining ring 26. Valve
7. Socket head cap screw 17. Roller bearing 27. Adjusting washer
8. Rod 18. Retaining ring 28. Retaining ring
9. Piston 19. Rotary shaft lip seal
10. Valve cone 20. Housing
BKF0004EN_D0024710002_04 2010-06-09 15
3.3 Types of seals
Tab. 3.6: Types of seals KF 4...80
Pump with single rotary Pump with single rotary Pump with double rota- Pump with double rota-
shaft lip seal shaft lip seal and out- ry shaft lip seal with ry shaft lip seal for vac-
Mounting: F / W board bearing connection borehole G uum operation with
Sealing materials: Mounting: G / X 1/8 for liquid seal connection borehole G
1: NBR Sealing materials: (Quench) 1/8 for liquid seal
2: FKM 1: NBR Mounting: F / W (Quench)
3: PTFE 2: FKM Sealing materials: Special number 74
9: EPDM 3: PTFE 4: PTFE Mounting: F / W
23, 31: FKM (low tem- 7: FKM Sealing materials:
perature) 19: NBR 4: PTFE
32: EPDM 7: FKM
19: NBR
32: EPDM
Pump with triple rotary Pump with mechanical Pump with mechanical Pump without shaft
shaft lip seal for vac- seal seal and connection G seal
uum and normal oper- Mounting: F / W 1/8 (KF 4...25) or G 1/4 Mounting: F / W
ation with connection Sealing materials: (KF 32...80) for liquid Sealing material:
borehole G 1/8 for liq- 5: FKM seal (Quench) 30: FKM (O-Ring)
uid seal (Quench) 6: PTFE Special number 198
Mounting: F / W 20: EPDM Mounting: F / W
(on request) Sealing materials:
5: FKM
16 2010-06-09 BKF0004EN_D0024710002_04
3.4 Type key
Tab. 3.7: Ordering example KF 4...80
KF 40 R F 1 /... - D 15 - ...
1. 2. 3. 4. 5. 6. 7. 8.
Tab. 3.8: Explanation of type key KF 4...80
Explanation of type key KF 4...80

1. Product name
2. Nominal size
Vg Size 1: 4, 5, 6, 8, 10, 12, 16, 20, 25 cm3
Size 2: 32, 40, 50, 63, 80 cm3
3. Direction of rotation
R Right B Right and left
L Left U Universal (Direction of rotation right and left,
direction of discharge consistent)
4. Mounting
F DIN flange without outboard bear- W Mounting angle without outboard bearing
ing
G DIN flange with outboard bearing X Mounting angle with outboard bearing
5. Seal type
1 Single rotary shaft lip seal NBR 18 Single rotary shaft lip seal BAUMX7 FKM
2 Single rotary shaft lip seal FKM 19 Double rotary shaft lip seal NBR
3 Single rotary shaft lip seal PTFE 20 Mechanical seal with EPDM secondary seal
(not resistant to mineral oil)
4 Double rotary shaft lip seal PTFE 23 Single rotary shaft lip seal MSS-1 FKM
(low temperature)
5 Mechanical seal with FKM secon- 30 Without shaft seal, O-Ring FKM
dary seal (external leak oil discharge)
6 Mechanical seal with PTFE secon- 31 Single rotary shaft lip seal BABSL FKM
dary seal (low temperature)
7 Double rotary shaft lip seal FKM 32 Double rotary shaft lip seal EPDM
9 Single rotary shaft lip seal EPDM
6. Special number for specific types
See section "Important special numbers"
7. Pressure relief valve (only for direction of rotation R or L)
D 15 Adjustable from 0 - 15 bar D 25 Adjustable from 15 - 25 bar
BKF0004EN_D0024710002_04 2010-06-09 17
Explanation of type key KF 4...80

8. Housing and cover material
Not specified: EN-GJL-250 (GG-25)
GJS EN-GJS-400-15 (GGG-40)
3.5 Important special numbers
Tab. 3.9: Important special numbers KF 4...80
Special Description
number
74 Pump with double rotary shaft lip seal for vacuum operation with mounting hole for
liquid seal (quench), inner rotary shaft lip seal mounted with sealing lip towards shaft
end
158 SAE ¾ connections for KF 4...12, SAE 1 connections for KF 16...25
197 Noise-optimized version for aerated oils and vacuum
198 Lip-type seal with connection for liquid seal (quench)
232 SAE 2 connections for KF 50...80
304 Bearing bushings Iglidur X
317 Noise-optimized version for aerated oils and vacuum, bearing bushings Iglidur X
332 Version for low-viscous media (only in connection with material GJS), bearing bushings
Iglidur X, νmin = 4 mm²/s at max. 10 bar
353 Noise-optimized version for aerated oils and vacuum, bearing bushings DP4 (lead-free)
355 Bearing bushings Iglidur X, SAE ¾ connections for KF 4...12, SAE 1 connections for
KF 16...25
363 Version for low-viscous media (only in connection with material GJS), bearing bushings
Iglidur X, νmin = 4 mm²/s at max. 10 bar, SAE ¾ connections for KF 4...12, SAE 1
connections for KF 16...25
Air trapped in the medium or too high negative pressure can result in de-
livery rate reduction for pumps in noise-optimized version.
Measures for noise optimisation are only feasible for one rotational direction
and only effective for aerated oils or vacuum.
18 2010-06-09 BKF0004EN_D0024710002_04
4 Technical data
4.1 General characteristics
Tab. 4.1: General characteristics KF 4...80
General characteristics KF 4...80

Construction External gear pump
Materials See section "Overview of materials"
Fixing type Flange DIN ISO 3019
End of drive shaft ISO R 775 short-cylindrical
Pipe connection KF 4...12 Whitworth pipe thread G 3/4
KF 4...12/158 Flange connection SAE 3/4
KF 16...25 Whitworth pipe thread G 1
KF 16...25/158 Flange connection SAE 1
KF 32...80 Flange connection SAE 1 1/2
KF 50...80/232 Flange connection SAE 2
Installation position KF ...R/L/B... without quench Arbitrary*
KF ...R/L/B... with quench Horizontal, quenching connec-
tion on top
KF ...U... Horizontal, pressure connection
on top
Viscosity νmin 12 mm2/s**
νmax 20000 mm2/s
Ambient tempera- ϑu min -20 °C
ture ϑu max 60 °C
Speed n See section "Overview of nominal sizes"
Fluid temperature ϑ
Operating pressure pe and See section "Overview of operating pressure and fluid temperature "
pb
Filtering Filter porosity ≤ 60 µm
Permissible media Fluids without abrasive components which are compatible with the
pump materials used. The fluids must guarantee minimum lubrica-
tion. Media-specific characteristics must be taken into account.
Petrols, solvents, etc. are not permissible.
* A reduced service life must be expected for the shaft seal when vertically installed.
** Lower viscosities only in connection with GJS housings and reduced pressures (consult manu-
facturer).
BKF0004EN_D0024710002_04 2010-06-09 19
4.2 Overview of nominal sizes
Tab. 4.2: Nominal sizes KF 4...80
Nominal Geom. Speed Permissi- Sound Weights

size* delivery ble radial level kg
volume nmin nmax force** LpA with cover with D- with
Vg Fradial db(A) valve univer-
1/min rpm
cm3 N sal de-
(n=1500 vice
rpm
4 4,03
5 5,05
6 6,38 2,9*** 3,7***
6,9
8 8,05 4,2**** 5,0****
10 10,11 200 3000 700 ≤ 65
12 12,58
16 16,09
3,5*** 4,3***
20 20,10 7,5
4,8**** 5,6****
25 25,10
32 32,12
40 40,21 7,7 9,5 27,5
50 50,20 200 3000 1500 ≤ 68
63 63,18
9,4 11,2 29,5
80 80,50
* See type key and type designation at pump: KF ...
** Radial forces only at version with outboard bearing. Fradial on central shaft end.
*** Valid for pump KF 4...25 with Whitworth pipe thread.
**** Valid for pump KF 4...25 with flange connection SAE.
4.3 Recommended speed
Tab. 4.3: Discharge pumps recommended speed
Kinematic viscosity v in mm2/s

< 300 300 500 1000 2000 3000 6000 10000 20000 30000
≥ 1450 1250 1000 750 600 500 400 300 200 100
Speed nmax in rpm
20 2010-06-09 BKF0004EN_D0024710002_04
4.4 Overview materials
Tab. 4.4: Materials KF 4...80
Seal Housing/ Gear Bearing Shaft seal O-Rings

type* Cover
1 NBR NBR
2 FKM FKM
3 PTFE FEP
4 PTFE FEP
5 CrMo-casting/ FKM
Carbon in syn-
thetic resin,
FKM, 1.4571,
1.4401
6 SiC-Si/SiC-Si FEP
(KF 4...25), SiC-
DU, P10 Si/Carbon in
synthetic resin
(Steel,
(KF 32...80),
sintered bronze,
EN-GJL-250 FFKM, 1.4571
PTFE, Pb)
7 (GG-25) Carburising steel FKM FKM
Iglidur X
EN-GJS-400-15** (1.7139)
9 DP4 EPDM EPDM
(GGG-40)
18 (Steel, FKM FKM
sintered bronze,
19 NBR NBR
PTFE)
20 SiC-Si/Carbon, EPDM
CrNi-steel,
CrNiMo-steel
23 FKM (low tem- FKM (low
perature) tempera-
ture)
30 Without shaft FKM
seal
31 FKM (low tem- FKM (low
perature) tempera-
ture)
32 EPDM EPDM
** For version in EN-GJS-400-15 type designation: KF ... - GJS
BKF0004EN_D0024710002_04 2010-06-09 21
4.5 Overview of operating pressure and fluid temperature
Tab. 4.5: Operating pressure and fluid temperature KF 4...80
Type of seal* Operating pressure Fluid temperature

Suction side Pressure side
pe min bar** pe max bar pb bar pb max bar ϑmin °C ϑmax °C
(perm. continu- (pressure peaks)
ous pressure)
1 1 90
2 2-6**** 150
3
2 200
4
5 150
10
6 - 10 200
7 2-6**** 150
9 - 0,4*** 120
0,5
18 150
19 1 25 40 90
20 10 120
23 0,5 -30
30 25 -10 150
31 1 -30
32 0,5 120
4/74 200
7/74 -10 150
-0,9 0,2
19/74 90
32/74 120
** Heed restrictions of pe min = -0,35 bar for universal design (KF .. U).
*** Temporary during start-up condition: -0,6 bar
**** See table "Permissible operating pressures pe max for seal types 2 and 7" for permissible pres-
sures
22 2010-06-09 BKF0004EN_D0024710002_04
Tab. 4.6: Permissible operating pressures pe max for seal types 2 and 7
Max. speed nmax in rpm Permissible pressure pe max in bar

750 6
1000 5
1500 4
2000 3
3000 2
NOTICE
The stated minimum or maximum characteristics cannot be applied for cer-
tain operating conditions.
As a result, for example, maximum operating pressure is not permissible in
connection with low speed and/or viscosity.
The media-specific characteristics must be taken into account, for example,
the operating temperature of aqueous dispersions and solutions is limited
to 50 °C and the pump must be arranged below the liquid level and the
speed limited to max. 1500 rpm.
4.6 Dimensions
Dimensions of the device can be found in the relevant technical data sheets.
BKF0004EN_D0024710002_04 2010-06-09 23
5 Transport and storage
5.1 Transport damage
Inspect the device for shipping damage as soon as the delivery has been
received.
If shipping damage is discovered, inform the shipping company.
If proper operation of the device is impaired by the damage, the device must
be replaced or repaired. In that case, contact the manufacturer.
5.2 Transport
DANGER
device.
The unit's centre of gravity must lie between the lifting tackle mounting
points on the unit.
24 2010-06-09 BKF0004EN_D0024710002_04
When transporting individual pumps, the eyebolts can be screwed into the
connecting flange as a handling aid.
Tab. 5.1: Examples for safe transport of pumps
DANGER
For pump units: never use eyelets on the motor to transport the pump units.
They can only support the weight of the motor.
Tab. 5.2: Examples for safe transport of pump units
BKF0004EN_D0024710002_04 2010-06-09 25
5.3 Corrosion protection
The device's function is tested in the plant with mineral hydraulic oil. Then all
connections are closed. The remaining residual oil protects the interior parts
for about 6 months.
Clean bare outer metal parts have also been protected by anti-corrosive oil
or protective metal paint for a period of 6 months against corrosion.
The device must not be exposed to the influence of the weather and major
fluctuations in temperature during transport and storage and must be stored
in a dry place.
If the device is stored over a longer period, it must be treated on the inside
and outside with a suitable corrosion protection oil. In addition, it must be
protected from humidity by a humidity-absorbing agent.
If high air humidity or aggressive atmosphere is to be expected during trans-
port, suitable corrosion prevention measures must be carried out.
NOTICE
Care must be taken that the preserving agent is compatible with the mate-
rials and elastomers used. In addition, compatibility with the media used
must be guaranteed.
The functionality of devices with EPDM seals is not being tested. Preser-
vation of the interior parts does not take place. The customer needs to carry
out appropriate corrosion prevention measures in cases where the device
is not immediately put in operation.
26 2010-06-09 BKF0004EN_D0024710002_04
6 Installation
6.1 General points
NOTICE
All work on the device may only be carried out by trained and professionally
qualified staff.
During all work, care must be taken that everything remains absolutely
clean.
6.2 Noise reduction
In view of optimising noise protection, it is advisable to mount a bellhousing

with vibration damper between pump and motor as well as vibration damp-
ers between motor and mounting surface. Suction and pressure piping must
be able to move freely or it needs to be elastically suspended.
Installation of suction and pressure hoses diminishes the noise level of hy-
draulic systems. Some hose manufacturers offer special, highly flexible
suction hoses for this purpose.
Installation of the pump above the liquid level diminishes the noise level of
hydraulic systems. The negative pressure pe on the pump's suction port
should be approx. -0,1 ... -0,2 bar.
6.3 Definition of the direction of rotation and pumping flow
WARNING
machine.
BKF0004EN_D0024710002_04 2010-06-09 27
6.3.1 KF 4...80
Tab. 6.1: Rotation and delivery direction KF 4...80
The following definition shall apply with respect to the rotation and delivery
direction of external gear pumps in case of pump connections being posi-
tioned below the drive shaft:
Looking at the pump shaft end, the Looking at the pump shaft end, the
pumping flow is from left to right pumping flow is from right to left
when the shaft is moving clock- when the shaft is moving anticlock-
wise. wise.
Without pressure relief valve
ps = Suction side pd = Pressure side

With pressure relief valve
28 2010-06-09 BKF0004EN_D0024710002_04
6.3.2 KF 4...25 U
Tab. 6.2: Rotating and delivery direction KF 4...25 U
With regard to the direction of rotation and pumping flow of pumps with
universal device KF 4...25 the following definition shall apply when looking
at the pump shaft end:
Direction of rotation right Direction of discharge consistent
and left
6.3.3 KF 32...80 U
Tab. 6.3: Rotating and delivery direction KF 32...80 U
With regard to the direction of rotation and pumping flow of pumps with
universal valve KF 32...80...U2 the following definition shall apply when
looking at the pump shaft end:
Direction of rotation right and left Direction of discharge consistent
BKF0004EN_D0024710002_04 2010-06-09 29
6.4 Change of the direction of rotation
NOTICE
This conversion may only be carried out by trained and experienced per-
sonnel.
All warranty claims and manufacturer responsibility shall be void when im-
proper conversion work takes place.
Cover or pressure relief valve are fixed by clamping sleeves. The bearing
must not be damaged e.g. through tilting during assembly and disassembly
of the cover and pressure relief valve respectively. Furthermore, the O-ring
must not be removed, damaged or clamped.
Change of the direction of rotation in the case of KF...R... and KF...L... pump
types, i.e. pure clockwise or anticlockwise rotating pumps, is only possible by
converting the pump.
The manufacturer normally carries out the conversion work and the customer
should do this only in case of an emergency.
Pumps in noise-optimized version cannot be converted.
Tab. 6.4: Change of the direction of rotation KF ...R... und KF ...L...
ps = Suction side * Fastening screws

pd = Pressure side ** Leak oil hole
In case of a pump's change of the direction of rotation the cover and/or pres-
sure relief valve must be rotated through 180°.
● Loose fastening screws.
● Remove the cover or the pressure relief valve respectively from the pump
housing and put it back on rotated by 180°.
● Tighten all fastening screws applying the below mentioned tightening
torques (see table "Tightening torques for fastening screws").
When checking, pay attention to the following points:
● Pumps without pressure relief valve must have their leak oil hole on the
interior cover side at the pump's suction side.
30 2010-06-09 BKF0004EN_D0024710002_04
● Pumps with pressure relief valve must have their pressure relief valve
adjusting screw point toward the pump's pressure side.
Tab. 6.5: Tightening torques for fastening screws
Nominal size* 4 ... 25 32 ... 80

Tightening torque 25 Nm 49 Nm
In the case of pumps having seal type 6, the mechanical seal must be re-
placed in addition. During this process, the spring coiling direction must be
observed. Heed the assembly instructions of the respective manufacturer
when replacing the mechanical seal.
BKF0004EN_D0024710002_04 2010-06-09 31
6.5 Design of suction and pressure line
DANGER
may be used.
NOTICE
Pipelines must be fitted absolutely tension-free to the device connections.
Pipelines must be designed in such a way that no tension e.g. caused by
changes in length due to fluctuations in temperature can be transferred to
the device.
Installation of suction and pressure hoses diminishes the noise level of hy-
draulic systems. Some hose manufacturers offer special, highly flexible
suction hoses for this purpose.
6.5.1 Suction line
NOTICE
Suction line concept development must be carried out with extreme care
since this will strongly influence the pump's performance.
The suction line must be piped as short as possible and in a straight line.
Avoid large suction heights.
Additional line resistances such as formed parts, fittings and closed meshed
suction filters increase the pipe resistance of the suction line and must be
avoided.
The negative pressure in the suction line is calculated from the sum of all
suction-side resistances and the suction height considering the media-spe-
cific data.
The negative pressure can be controlled by fitting a vacuum gauge to the

pump suction line connector.
Ensure proper suction when piping the suction line and the distances to the
floor and to the bulkhead partitions must be sufficiently large.
The inlet port must have a sufficient distance to the lowest fluid level.
32 2010-06-09 BKF0004EN_D0024710002_04
The nominal width of the suction line may actually be selected to be larger
than the pump connection.
Funnel-shaped formation of the suction port at the pump suction side or

obliquely cutting the suction pipe end is recommended for enlargement of
the suction cross section.
When hose lines are used on the pump suction side, care must be taken to
ensure that the hoses are of sufficient stability so that they will not be con-
stricted through the sucking action.
The media-specific data need to be observed, for example, the device must
be arranged below the fluid level in case of aqueous dispersions and solu-
tions.
The recommended flow velocity in the suction line is max. 1,5 m/s.
Tab. 6.6: Piping the suction line as siphon
If there is a possibility that the suction line

can run dry if the pump stops, piping the
suction line as siphon is an option to avoid
suction problems. This way, the pump will
remain permanently filled after initial com-
missioning.
It is appropriate to employ a foot valve or a
non-return valve in cases of longer suction
lines that can run dry while the pump is at
rest. These must have been designed for
use in suction lines and should offer as low
a flow resistance as possible.
Tab. 6.7: Suction line at vacuum operation
If the pump is to intake from a tank under

vacuum, the pump must be arranged ap-
prox. 0.8 m below the tank. The suction line
must run in a straight line and without any
resistances.
The tank may be subjected to vacuum only
then when the pipework and the pump have
been filled with liquid.
For this application, only pumps designed
as a vacuum system may be employed.
* = Vacuum
BKF0004EN_D0024710002_04 2010-06-09 33
NOTICE
The permissible pressure at the pump inlet shall not be lower than value
pe min as stated in chapter "Technical data".
If the permissible value should exceed the lower limits, this will result in a
drop of delivery (due to pump short filling), high noise emission and cavi-
tation.
An exception to this is the pump's start-up condition at which a pressure of

-0.6 bar (negative pressure) is tolerable for max. 30 minutes.
NOTICE
The pressure at the pump inlet must not exceed the value of pe max as stated
in chapter "Technical data" as otherwise there is a risk of impermissible
heating and increased wear on the shaft seal.
6.5.2 Pressure line
DANGER
ments.
The nominal width of the pressure line must be selected such that the maxi-
mum permissible pressures are not exceeded.
The pressure must be checked by a manometer installed as closely as pos-
sible to the pressure connection.
To avoid pump overload caused by an impermissibly high pressure, a pres-
sure relief valve or a rupture disc with return to the supply tank must be
installed as closely as possible to the pump's pressure connection.
Another option of pressure limiting is to mount a pressure relief valve directly
to the pump.
During operation of a pump that has to pump media via a non-return valve in
a pressurized circuit (e.g. reserve pump in a lubricant circuit), intake problems
can occur if the inlet pipe is filled with air. In this case the pressure pipe must
be bled directly upstream of the non-return valve.
This can be carried out by a bleeding valve with return or a throttled bypass,
for example.
34 2010-06-09 BKF0004EN_D0024710002_04
Tab. 6.8: Bleeding valve and throttled bypass
Bleeding valve with return Throttled bypass
If none of the measures described is carried out, the volume of the pressure
pipe between the pump and the non-return valve must be at least 75 % of the
inlet pipe volume.
BKF0004EN_D0024710002_04 2010-06-09 35
6.6 Mounting the clutch
NOTICE
When dimensioning the clutch, pay attention to safe dimensioning so as to
transfer the expected maximum torque reliably and permanently.
Vibrations, torque peaks and temperatures need to be taken into account.
The permissible values of the clutch manufacturer must not be exceeded.
Heed the clutch manufacturer's installation instructions.
When mounting the clutch, keeping the "E" measure exactly is of the essence
so that the clutch will remain axially movable when used. In order to avoid
any frontal pressure against the elastic gear rim, measure "E" should each
be considered as minimum in the case of an axial displacement.
If the shaft clearance is less than clutch clearance "E", one of the shaft ends
can easily extend into the gear rim. Size "dW" corresponds to the max. shaft
diameter that may extend with the parallel key into the gear rim, size "dH". If
there is the chance to offset the parallel key, i.e. only the shaft extends into
the gear rim, the size of the shaft may be increased up to 2 mm below the
specified "dH" size in order not to obstruct the gear rim in its axial movability.
The permissible displacement values of the elastic clutches stated represent
general guide values taking a clutch loading up the the clutch nominal torque
and an operating speed n = 1500 rpm as well as an occurring ambient tem-
perature of +30 °C into account. Consultation with the manufacturer is
necessary for deviating operating conditions.
The displacement data may only be used individually in each case and in case
of simultaneous appearance in proportion only.
Careful and exact shaft alignment increases clutch life.
36 2010-06-09 BKF0004EN_D0024710002_04
Fig. 6.1: Displacements - aligning the clutch
* Clutch clearance "E"

** Shaft with parallel key extends into the gear rim (dw)
Tab. 6.9: Types of coupling
19 24 28 38 42 48 55 65 75
Type of coupling*
19/24 24/28 28/38 38/45 42/55 48/60 55/70 65/75 75/90
Clutch clearance** E 16 18 20 24 26 28 30 35 40
Dimension** s 2 2 2,5 3 3 3,5 4 4,5 5
Dimension** dH 18 27 30 38 46 51 60 68 80
Dimension** dW 12 20 22 28 36 40 48 55 65
Max. axial displace- ΔKa 1,2 1,4 1,5 1,8 2,0 2,1 2,2 2,6 3,0
ment**
Max. radial displace- ΔKr 0,20 0,22 0,25 0,28 0,32 0,36 0,38 0,42 0,48
ment**
n=1500 1/min
Max. angular dis- ΔKw 1,2° 0,9° 0,9° 1,0° 1,0° 1,1° 1,1° 1,2° 1,2°
placement
n=1500 rpm
* Example: RA19-Z25/14-Z25/19 or RA19/24-Z25/14-Z25/24
** Dimensions in mm
NOTICE
The respective manufacturer's installation instructions must be observed
when using other clutch types.
BKF0004EN_D0024710002_04 2010-06-09 37
NOTICE
Do not knock onto the shaft during installation of the clutch halves!
The hubs should be heated for mounting the clutch and slid onto the shaft
while hot.
Using a pinion gear drive, it must also be heated and slid onto the shaft end
while hot.
NOTICE
Every clutch hub for cylindrical shafts must be secured on the respective
shaft against axial displacement using a set screw that presses against the
parallel key.
DANGER
38 2010-06-09 BKF0004EN_D0024710002_04
6.7 Mechanical installation
NOTICE
qualified staff.
clean.
It must be guaranteed that all lines and connections are tight and no leak-
ages can occur or air be sucked in.
● Before installation, the device must be checked for transport damage and
soiling.
● Any preserving agents must be removed before installation using ben-
zine or solvent.
● Clean the pipework of dirt, scale, sand, swarf, etc. prior to installation.
Welded pipes in particularly must be pickled or flushed. Cotton waste
must not be used for cleaning.
● Mount clutch and clutch halves respectively to pump and drive (see sec-
tion "Mounting the clutch").
DANGER
● Mount pump to bellhousing, foot or housing and pay attention to careful

alignment and correct fitting position (see chapter "Technical data").
● Tighten all fastening screws applying the torque as prescribed by the
manufacturer of the bellhousing avoiding any twisting of the pump in the
process without fail.
● Remove the protective plugs in the pump's suction and pressure con-
nections.
DANGER
BKF0004EN_D0024710002_04 2010-06-09 39
WARNING
Hazard caused by shearing in case of rotating gears
Device must only be put in operation with its lines connected.
● Wet devices interiors with fluid being pumped.
DANGER
may be used.
NOTICE
the device.
● During installation, make sure that no sealant gets into the pipeline.
Sealing agents such as hemp and putty are not permitted since they can
lead to soiling and thus to functional problems.
● Connect suction and pressure side according to the marking on the pump
or the information on the type plate (see section "Definition of the direc-
tion of rotation and pumping flow").
● Connect the pipework to the suction and pressure piping. Always heed
the respective manufacturer's instructions.
● Mount a suitable tank for the liquid seal (see chapter "Operation start-
up", if applicable) when operating the pump with liquid seal (quench).
DANGER
ments.
40 2010-06-09 BKF0004EN_D0024710002_04
CAUTION
above 60°C.
NOTICE
Ensure that filling of the reservoir is carried out in absolutely clean condi-
tions.
● Before opening, clean filler screw and shutoff on fluid transport and stor-
age tank.
● Check media tank for contamination and clean if necessary. On no ac-
count remove the filter screen on the filler neck or the filter insert during
the filling process.
● Filling the media tank with the prescribed fluid.
● Ensure sufficient filling of the media tank!
6.8 Assembly with further components and devices
NOTICE
The operator's and maintenance instructions of the respective manufac-
turers must be observed during assembly with further components and
devices respectively. It is the only way to ensure safe and problem-free
operation.
DANGER
WARNING
machine.
BKF0004EN_D0024710002_04 2010-06-09 41
● All data stated on the motor type plate must be checked for conformity
to the required operating data.
● Adjust the overload protection to the correct value.
● Check the rotational drive direction of the pump before switching on.
42 2010-06-09 BKF0004EN_D0024710002_04
7 Operation start-up
7.1 Preparation
NOTICE
qualified staff.
clean.
Before starting the system make sure that a sufficient quantity of the oper-
ating medium is available so as to avoid dry operation.
Before starting the plant, pumps and suction line must be filled with oper-
ating fluid to prevent damage to the pump and the shaft seal during dry
operation. That also guarantees pump suction.
For pumps with liquid seal (quench), fill the sealing cavity with a suitable
confining fluid before it is used for the first time.
● Check the permissible operating data against the operating states to be

expected.
● Check all fastening screws on the device.
● Fill the pump and suction line with the operating fluid.
● In the case of pumps with liquid seal (quench), fill the sealing cavity using
an appropriate confining fluid (see section "Pumps with liquid seal
(quench connection)").
● Checking the direction of rotation. See section "Change of the direction
of rotation" in chapter "Installation" for any change in rotational direction.
BKF0004EN_D0024710002_04 2010-06-09 43
7.2 Pumps with liquid seal (quenching connection)
7.2.1 Description
NOTICE
Fill the pump sealing cavity with a suitable confining fluid.
The confining fluid must be compatible with the seals and materials used
as well as with the pumping medium.
The confining fluid's minimum and maximum filling level must be ensured
using appropriate technical and/or organisational measures.
The liquid seal in the quenching connection must not be subjected to pres-
sure or vacuum.
If fluids are delivered

● that cure in air,
● crystallise in contact with air humidity,
● the leakage of which must not be released into the environment,
● are under vacuum and their seal shall be gastight,
then the employment of a double seal with liquid seal is necessary.
● A tank for the liquid seal is to be connected to the quenching connection.
Suitable tanks are available from the manufacturer.
● The tank for the liquid seal must be placed above the pump.
● The installation position is restricted and the quenching connection shall
be directed upwards.
● Check of the fluid level in the tank must be possible at any time.
A second port on the device enables purging of the sealing cavity and
draining of the seal liquid.
44 2010-06-09 BKF0004EN_D0024710002_04
7.2.2 Versions
Tab. 7.1: KF 4...80 with liquid seal (Quench)
Types of seals: Types of seals: Triple rotary shaft lip Type of seal: 5
4, 7, 19, 32 4, 7, 19, 32 seal Special number 198
Special number 74 (on request)
BKF0004EN_D0024710002_04 2010-06-09 45
7.3 Setting the pressure relief valve
Applies for pumps with built-on pressure relief valve

(Type designation: KF ... - D15 or KF ... - D25)
Fig. 7.1: Pressure setting KF 4...80 - D..
- response pressure lower

+ response pressure higher
NOTICE
The series D.. pressure relief valves are exclusively used to secure the
pump. The valves may only respond for brief periods.
Permanent drawing off the delivery via the valve will destroy the pump
through overheating.
For pressure setting on the pressure relief valve:

● loosen the hexagon nut (1)
● adjust set screw (2)
clockwise = response pressure higher
anticlockwise = response pressure lower
● secure the set screw (2) using hexagon nut (1) once the desired pressure
has been adjusted.
DANGER
Securing screw (3) on the valve must not be slackened!
At loosened securing screw, the set screw (2) can be screwed into the valve
until it is completely shut.
This can result in inadmissibly high pressures in the system if there is no
other pressure relief device.
Fluid can spurt out from the valve in case of fully screwed out set screw (2).
46 2010-06-09 BKF0004EN_D0024710002_04
7.4 Further operation start-up
● The pumps may only start without or with low pressure load. For this
purpose, open the existing shut-off elements and adjust the pressure
relief valve incorporated in the pressure pipe to the lowest opening pres-
sure.
● Start-up takes place by repeated quick on-off switching of the driving
motor (jog mode) without reaching full speed until proper operation of the
device is evident. This applies particularly when a cold pump is to start
with already heated medium. The reason for this is to achieve slow heat-
ing of the pump and prevent the pump seizing through thermal shock.
● Proper function indicated by noise generation or on the pressure gage
should be reached after max. 30 seconds.
● First of all, run the pump at zero pressure or low pressure for a couple
of minutes after switching on the motor.
● Bleed the plant on the distribution pipes, preferably at the highest point.
● Pressure loading can be gradually increased up to the desired operating
pressure.
● Check the temperature of the medium and that of the pump after the
intended operating characteristics have been reached. Checkpoints on
the pump are the bearing locations, the housing and the shaft seal. The
temperatures observed on the pump surface may be approx. 10 °C
above medium temperature.
● Check the fluid level of the plant once more and top up if necessary.
● Check the final operating temperature after several hours running time
(see chapter "Technical data" for max. permissible temperatures).
● Check the static seals on the suction and pressure connections and the
pump's joints for leakages.
● Check the threaded connections for leakages. Such leakages can be
easily eliminated by simply retightening the threaded connections.
● Also check all motor and pump fastening screws after a few hours of
operation.
BKF0004EN_D0024710002_04 2010-06-09 47
8 Removal
8.1 General points
NOTICE
qualified staff.
clean.
Close all openings with protective caps to prevent dirt from penetrating into
the system.
8.2 Disassembling the pump
DANGER
DANGER
CAUTION
● Remove the depressurised pipelines from the pump.

● Seal the pump connections and pipelines to prevent dirt penetration.
● Disassemble the pump
● Pull off clutch hub resp. the driving pinion from shaft end using an ex-
tractor.
48 2010-06-09 BKF0004EN_D0024710002_04
● Immediately clean the pump or store it in such a way that curing is defi-
nitely prevented in cases where the pump was operated with curing
liquids.
BKF0004EN_D0024710002_04 2010-06-09 49
9 Maintenance
9.1 General points
NOTICE
Regular maintenance is essential for safe operation. Scope and intervals
must be adapted to requirements. The first check-up must be carried out
directly after the device has been put into operation.
The length of maintenance intervals must be defined by the operator. Dur-
ing visual inspections, particular attention must be paid to possible damage.
In this case, the device may no longer be used.
Type and scope of maintenance as well as measured values should be
documented. This is the quickest way to determine changes in operating
data.
When designed to the conditions of use and fitted correctly, the devices are
able to be used for long and problem-free operation. They only require a little
maintenance. This is absolutely essential for problem-free operation, howev-
er. Experience shows that a high percentage of the problems and damage
that occur can be traced back to dirt and lack of maintenance.
The scope and time intervals for inspections and maintenance are generally
specified by the operator in a respective plan.
All removed barriers and warning signs must be put back to their original
position on completing maintenance and/or repair.
Regular checking of all operating data such as pressure, temperature, cur-

rent consumption, degree of filter soiling etc. contributes to early problem
detection.
NOTICE
qualified staff.
clean.
the system.
50 2010-06-09 BKF0004EN_D0024710002_04
DANGER
DANGER
DANGER
DANGER
ments.
DANGER
CAUTION
BKF0004EN_D0024710002_04 2010-06-09 51
9.2 Unusual noises
Some damage is indicated by unusual noises. If there is a change in the de-

vice's operating noise, a thorough examination of the cause must always take
place.
9.3 Cleaning
The pump shaft as well as the associated hardware must not run in dust ac-
cumulations.
Regular cleaning of the pump and its environment is therefore necessary.
Cleaning the pump using a steam jet cleaner is not permissible.
9.4 Static seals
The static seals on the device's separation joints and the connection lines
must be periodically checked for leakproofness.
If there are any visible leaks, immediately stop plant operation.
If the leaks cannot be stopped by simply retightening the connection, replace
all affected seals.
9.5 Confining fluid level
Checking the confining fluid filling level is mandatory for safe pump operation.
Top up the confining fluid as required.
If there is no automatic monitoring, the filling level must be checked at least
before each shift begins.
The outer but also the inner shaft seal could be leaking if the filling level should
drop unusually fast within a short period of time. The confining fluid will then
leak into the coupling space or it will be sucked into the pump thereby mixing
with the medium.
If the filling level should rise, the inner shaft seal may probably be leaking and
the confining fluid is being mixed with the pressurised medium.
Stop plant operation immediately in both cases.
9.6 Rotary shaft lip seals
Rotary shaft lip seals are particularly prone to wear for functional reasons and
must accordingly be carefully checked. Too high admission pressure, wrong
rotational direction or contamination lead to increased wear, increased leak-
age and impermissible temperature rises.
52 2010-06-09 BKF0004EN_D0024710002_04
Small amounts of leakage, however, are indispensable for function. The per-
missible amount of leakage, though, is highly dependent on the operational
conditions and cannot be quantified.
If there are excessive amounts of leakage, stop pump operation immediately.
Replace the rotary shaft lip seals.
Increased wear on the rotary shaft lip seal should be taken into account in the
case of vertical pump installation.
9.7 Mechanical seal
Mechanical seals are particularly prone to wear for functional reasons and
must accordingly be carefully checked. Too high admission pressure, wrong
rotational direction, frequent start-ups, gas or air portions in the oil or con-
tamination lead to increased wear, increased leakage and impermissible
temperature rises.
Small amounts of leakage, however, are indispensable for mechanical seal
function. The permissible amount of leakage, though, is highly dependent on
the operational conditions and cannot be quantified.
If there are excessive amounts of leakage, stop pump operation immediately.
Replace the mechnical seal. In so doing, heed the assembly instructions of
the mechanical seal manufacturer.
Increased wear on the mechanical seal should be taken into account in the
case of vertical pump installation.
9.8 Clutch
Clutches must be maintained according to the specifications of the respective

manufacturer.
9.9 Screw joints
All the screw joints must be checked at regular intervals to make sure they
are a tight fit. Loose screw joints must be tightened and, if necessary, secured
against loosening by e.g. Loctite (medium strength).
9.10 Damage
Check the pump as well as its environment regularly for damage such as
dents in the clutch guard.
BKF0004EN_D0024710002_04 2010-06-09 53
9.11 Surface temperature
For identifying premature wear or pump overload, it is useful to check the

temperatures on the pump surface at regular intervals.
This temperatures should never be much higher (max. 10 °C) than the media
temperature at the pump inlet. Checkpoints on the pump are the bearing lo-
cations, the housing and the shaft seal.
If the measured temperatures are higher than the permissible values, this is
an indication of wear or bearing damages. The pump must be replaced in this
case.
9.12 Bearings, gear, wheel chamber housing
Like shaft seals, bearings, gear and wheel chamber housings are wear items.
Wear largely depends on the occurring loads, life cycle as well as type and
proportion of solids in the medium. Wear cannot be identified from the outside.
The condition of a pump, however, can be analysed by the volumetric effi-
ciency factor. Decrease of the efficiency factor would normally indicate wear.
Therefore, a check on all operating data such as delivery, pressure, temper-
ature, drive data, degree of filter contamination should also be carried out
during maintenance work.
Further investigations into the cause are necessary in the event of major de-
viations (>10%) to the reference values. This helps detecting premature pump
failure in time. The pump must immediately be taken out of service at a drop
of delivery or pressure to 80 % of the original values. The achieved values at
initial commissioning serve as reference in this case.
54 2010-06-09 BKF0004EN_D0024710002_04
10 Repairs
10.1 General points
The term repairs covers:

● Troubleshooting, in other words establishing damage, determining and
localising the reason for the damage.
● Elimination of the damage, in other words eliminating the primary cau-
ses and replacing or repairing faulty components.
10.2 Troubleshooting
Leaks are the most frequent problem. If these occur on the pipelines, they
can be eliminated by straightforward tightening of the screw joints.
If the device itself is leaking, the respective seals have to be replaced (see
spare parts list).
10.3 Elimination of damage
Repair damage onsite, predominantly by replacing the defective device. The

device itself is generally repaired by the manufacturer.
If corresponding expertise and sufficient equipment is available, the consum-
er or OEM can also make the repairs. For support, spare parts lists and
sectional drawings are available. They can be requested from the manu-
facturer.
NOTICE
Repair work may only be carried out by trained and professionally qualified
staff. Only original spare parts may be used.
10.4 Return
If the device has to be repaired or checked over on the manufacturer's prem-

ises, it must be packed suitably for transport. In addition, a safety data sheet
for the medium used must be enclosed with the device. In the case of well-
known mineral oils, at least the exact type description is required.
If hardening or agglutinative media are involved, the device must be cleaned
before it is returned.
Cleaning is also necessary if the device has been operated with hazardous
fluids.
BKF0004EN_D0024710002_04 2010-06-09 55
10.5 Detecting and eliminating problems
The following table lists the possible causes of the most frequently occuring
malfunctions and notes on possible remedies.
If the problems cannot be identified, please request help from the manufac-
turer.
Tab. 10.1: Transfer pumps: Faults and causes
Fault Potential causes

Increased Pump ● Negative pressure too high causing pump short filling
noise cavitation ● Suction height too high
● Suction filter plugged or too small
● Inner diameter of suction line too small
● Suction line too long
● Too many bends in the suction line
● Too many local constrictions in the suction line
● Suction line plugged or leaking
● Too high viscosity
● Temperature too low
● Wrong direction of rotation
Foaming ● Suction line leaking
or trap- ● Fluid level in supply tank too low
ped air in
● Too little oil supply
medium
● Return line to tank leaking
● Wrong tank dimensioning
● Shaft seal or seal on suction line leaking
● Return line end above the fluid level in the supply tank
● Insufficient venting
● Too strong foaming in the gear
Mechani- ● Incorrectly aligned or loose clutch
cal vibra- ● Magnetic coupling defective
tions
● Faulty or insufficient line fastening
● Wobbling pressure relief valve
● No noise-optimized design (missing dampers)
● Unfavourable place of pump installation
● Pump worn out, tooth flanks worn out
● Disturbances in pump operation
56 2010-06-09 BKF0004EN_D0024710002_04

Pump does ● Too high negative pressure
not suck ● Fluid level in supply tank too low
● Magnetic coupling torn off
● Wrong direction of rotation
● Throttled shut-off element in the suction line
● Suction line too long
● Suction line leaking
● Suction resistance too high
● Foreign objects in suction line
● Volume of pressure pipe between pump and non-return valve too
little, pump cannot compress the air contained in the suction line
● Non-return valve not bled
● Too high start-up pressure if suction line is filled with air
● Speed too low
Insufficient ● Too high negative pressure
delivery ● Throttled shut-off element in the suction line
● Fluid level in supply tank too low
● Suction filter plugged or too small
● Too high viscosity
● Too low viscosity
● Too high speed
● Too high pressure
● Pressure relief valve set too low
● Pump sucks air
● Pump worn out
● Too high proportion of air in the oil
● Universal valve defective
Insufficient Delivery ● Too low viscosity
pressure too low ● Pressure relief valve set too low or does not shut
Work ● Too low speed
drags in
● Driving power too low
pressure
pipe too ● Pump worn out
low
Excessive ● Too high pressure
power con- ● Too high viscosity
sumption ● Driving power too low
● Motor winding defective
BKF0004EN_D0024710002_04 2010-06-09 57

Excessive ● Pressure relief valve set too high
operating ● Speed too high
temperature ● Cooling and heat dissipation insufficient
● Supply of fluid too low
● Fluid is being delivered into the supply tank via pressure relief valve
under load
Impermissi- ● Delivery-side valve cone not completely shut
ble ● Directly mounted pressure relief valve set too low (does not apply for
pump heat- the "universal valve" and "T-valve" versions)
ing ● Too high pressure
● Gland lid overtightened
● Separating can insufficiently bled
● Admission pressure impermissibly high
● Pump worn out
Leakages ● Admission pressure impermissibly high
on shaft seal ● Wrong direction of rotation
● Too high radial shaft loading
● Temperature at sealing point too high
● Wrong seal material
● Missing confining fluid
● Separating can defective
● Sealing wear due to poorly lubricating medium
● Sealing wear through abrasive components in medium
● Sealing wear through curing medium
● Gland lid not sufficiently tightened
Clutch wear ● Incorrectly aligned or loose clutch
● Axial clutch clearance insufficient
● Clutch overloaded
● Temperature too high
Magnetic ● Magnetic coupling under-dimensioned
coupling ● Pressure too high
torn off
● Driving motor oversized
● Too high starting torque
● Too high operating temperature
● Pump is blocking due to foreign objects
58 2010-06-09 BKF0004EN_D0024710002_04

Short opera- Wear on ● Wear through abrasive components
tional lives bearing, ● Wear due to poorly lubricating medium
gear and
housing
parts ● Check corrosion, material compatibility
● Too high operating pressure for the media properties
BKF0004EN_D0024710002_04 2010-06-09 59
EOM-P1M 3/02
REPLACES EOM-P1M 3/01
TABLE OF CONTENTS
PAGE #
SECTION #1 — PUMP DESIGNATION SYSTEM...................................... 1
SECTION #2 — HOW IT WORKS (PUMP & AIR SYSTEMS) ......... 2
SECTION #3 — CAUTIONS......................................................................................... 3
SECTION #4 — DIMENSIONAL DRAWINGS

A. Model P1 METAL................................................................................................................ 4
B. Model P1 METAL SANIFLOFDA ............................................................................................ 4
SECTION #5 — PERFORMANCE CURVES

A. Model P1 METAL Rubber-Fitted......................................................................................... 5
B. Model P1 METAL TPE-Fitted.............................................................................................. 5
C. Model P1 METAL Teflon®-Fitted.......................................................................................... 6
SECTION #6 — SUCTION LIFT CURVES & DATA.................................. 6
SECTION #7 — INSTALLATION & OPERATION

A. Installation........................................................................................................................... 7
B. Operation & Maintenance ................................................................................................... 8
C. Troubleshooting .................................................................................................................. 9
SECTION #8 — DIRECTIONS FOR DISASSEMBLY/REASSEMBLY

A. Model P1 METAL Wetted Path — Tools Required, Torque Specs, Cautions..................... 10
B. Pro-Flo™ Air Valve/Center Section — Disassembly, Cleaning, Inspection........................ 13
C. Reassembly Hints & Tips.................................................................................................... 15
SECTION #9 — EXPLODED VIEW/PARTS LISTING

A. Model P1 METAL Rubber/TPE-Fitted................................................................................. 16
B. Model P1 METAL Teflon®-Fitted.......................................................................................... 18
SECTION #10 — ELASTOMER OPTIONS ...................................................... 20
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WILDEN PUMP & ENGINEERING CO.
SECTION 1
WILDEN PUMP DESIGNATION SYSTEM
MODEL P1 METAL MATERIAL CODES

WETTED PARTS DIAPHRAGMS VALVE SEAT
A = ALUMINUM BN = BUNA-N (Red Dot) A = ALUMINUM
H = HASTELLOY FG = SANIFLEX™ (Cream) H = HASTELLOY
S = STAINLESS STEEL PU = POLYURETHANE (Clear) S = STAINLESS STEEL
TB = TEFLON® W/HI-TEMP BUNA-N
CENTER SECTION (White) VALVE SEAT O-RING
LL = ACETAL TF = TEFLON® W/NEOPRENE BN = BUNA-N (Red Dot)
PP = POLYPROPYLENE (White) FG = SANIFLEX™ (Cream)
VT = VITON® (Silver Dot) PU = POLYURETHANE (Brown)
AIR VALVE TF = TEFLON® PTFE (White)
WF = WIL-FLEX™ (Orange)
L = ACETAL WF = WIL-FLEX™ (Orange)
P = POLYPROPYLENE VALVE BALL
BN = BUNA-N (Red Dot)
FG = SANIFLEX™ (Cream)
PU = POLYURETHANE (Brown)
TF = TEFLON® PTFE (White)
VT = VITON® (Silver or White Dot)
WF = WIL-FLEX™ (Orange)
*O-RINGS NOT REQUIRED.
NOTE: MOST ELASTOMERIC MATERIALS USE COLORED DOTS FOR IDENTIFICATION.

Buna-N, Nordel and Viton are registered trademarks of DuPont Dow Elastomers.
Teflon is a registered tradmark of DuPont.
1 WILDEN PUMP & ENGINEERING CO.
SECTION 2
THE WILDEN PUMP — 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.
OUTLET OUTLET OUTLET
CLOSED OPEN OPEN CLOSED OPEN CLOSED
B A B A B A
OPEN CLOSED CLOSED OPEN CLOSED OPEN
INLET INLET INLET
RIGHT STROKE MID STROKE LEFT STROKE

FIGURE 1 The air valve directs pressurized air to FIGURE 2 When the pressurized diaphragm, FIGURE 3 At completion of the stroke, the air
the back side of diaphragm A. The compressed air is diaphragm A, reaches the limit of its discharge valve again redirects air to the back side of
applied directly to the liquid column separated by stroke, the air valve redirects pressurized air to the diaphragm A, which starts diaphragm B on its
elastomeric diaphragms. The diaphragm acts as a back side of diaphragm B. The pressurized air forces exhaust stroke. As the pump reaches its original
separation membrane between the compressed air diaphragm B away from the center block while starting point, each diaphragm has gone through
and liquid, balancing the load and removing pulling diaphragm A to the center block. Diaphragm one exhaust and one discharge stroke. This consti-
mechanical stress from the diaphragm. The B is now on its discharge stroke. Diaphragm B forces tutes one complete pumping cycle. The pump may
compressed air moves the diaphragm away from the the inlet valve ball onto its seat due to the hydraulic take several cycles to completely prime depending
center block of the pump. The opposite diaphragm is forces developed in the liquid chamber and manifold on the conditions of the application.
pulled in by the shaft connected to the pressurized of the pump. These same hydraulic forces lift the
diaphragm. Diaphragm B is on its suction stroke; air discharge valve ball off its seat, while the opposite
behind the diaphragm has been forced out to the discharge valve ball is forced onto its seat, forcing
atmosphere through the exhaust port of the pump. fluid to flow through the pump discharge. The move-
The movement of diaphragm B toward the center ment of diaphragm A toward the center block of the
block of the pump creates a vacuum within chamber pump creates a vacuum within liquid chamber A.
B. Atmospheric pressure forces fluid into the inlet Atmospheric pressure forces fluid into the inlet mani-
manifold forcing the inlet valve ball off its seat. Liquid fold of the pump. The inlet valve ball is forced off its
is free to move past the inlet valve ball and fill the seat allowing the fluid being pumped to fill the liquid
liquid chamber (see shaded area). chamber.
PRO-FLO™ AIR DISTRIBUTION SYSTEM

OPERATION — HOW IT WORKS
Figure A The Pro-Flo™ patented air distribution
system incorporates three moving parts:
MUFFLER PLATE the air valve spool, the pilot spool, and the
MAIN SHAFT SMALL END main shaft/diaphragm assembly. The heart
of the system is the air valve spool and air
MUFFLER
valve. As shown in Figure A, this valve
design incorporates an unbalanced spool.
The smaller end of the spool is pressurized
continuously, while the large end is alter-
nately pressurized then exhausted to
move the spool. The spool directs pressur-
ized air to one air chamber while exhaust-
PILOT ing the other. The air causes the main
SPOOL shaft/diaphragm assembly to shift to one
AIR VALVE SPOOL side — discharging liquid on that side and
LARGE END pulling liquid in on the other side. When the
shaft reaches the end of its stroke, the
inner piston actuates the pilot spool, which
CENTER SECTION END CAP 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.
WILDEN PUMP & ENGINEERING CO. 2

SECTION 3
WILDEN MODEL P1 METAL
CAUTIONS – READ FIRST!
TEMPERATURE LIMITS: CAUTION: Do not exceed 8.6 Bar (125 psig) air supply
Nylon –17.8°C to 93.3°C 0°F to 200°F pressure.
Neoprene –17.8°C to 93.3°C 0°F to 200°F CAUTION: Before any maintenance or repair is
Buna-N –12.2°C to 82.2°C 10°F to 180°F attempted, the compressed air line to the pump should be
Nordel® –51.1°C to 137.8°C –60°F to 280°F disconnected and all air pressure allowed to bleed from
Viton® –40°C to 176.7°C –40°F to 350°F pump. Disconnect all intake, discharge and air lines.
Wil-Flex™ –40°C to 107.2°C –40°F to 225°F Drain the pump by turning it upside down and allowing
Polyurethane 12.2°C to 65.6°C 10°F to 150°F any fluid to flow into a suitable container.
Saniflex™ –28.9°C to 104.4°C –20°F to 220°F
Teflon® PTFE 4.4°C to 148.9°C 40°F to 300°F* CAUTION: Blow out air line for 10 to 20 seconds before
*Teflon® PTFE upper temperature limit for UP Series with Hi-Temp attaching to pump to make sure all pipe line debris is
Buna backup diaphragm. Standard Teflon® PTFE diaphragms with clear. Use an in-line air filter. A 5µ (micron) air filter is
neoprene backup diaphragms are limited to 104.4°C (220°F). recommended.
CAUTION: When choosing pump materials, be sure to NOTE: Tighten clamp bands and retainers prior to instal-
check the temperature limits for all wetted components. lation. Fittings may loosen during transportation.
Example: Viton® has a maximum limit of 176.7°C (350°F)
but polypropylene has a maximum limit of only 79°C NOTE: When installing Teflon® diaphragms, it is impor-
(175°F ). tant to tighten outer pistons simultaneously (turning in
opposite directions) to ensure tight fit.
CAUTION: Maximum temperature limits are based upon
mechanical stress only. Certain chemicals will signifi- NOTE: Before starting disassembly, mark a line from each
cantly reduce maximum safe operating temperatures. liquid chamber to its corresponding air chamber. This line
Consult engineering guide for chemical compatibility and will assist in proper alignment during reassembly.
temperature limits. CAUTION: Verify the chemical compatibility of the
CAUTION: Always wear safety glasses when operating process and cleaning fluid to the pump’s component mate-
pump. If diaphragm rupture occurs, material being rials in the Chemical Resistance Guide (see E4).
pumped may be forced out air exhaust. CAUTION: Do not over-tighten the air inlet reducer
WARNING: Prevention of static sparking — If static bushing. Too much torque on the reducer bushing may
sparking occurs, fire or explosion could result. Pump, damage the air valve muffler plate. Do not exceed
valves, and containers must be properly grounded when 29 in.-lbs. [3.3 m-N].
handling flammable fluids and whenever discharge of
static electricity is a hazard.

SECTION 4A
DIMENSIONAL DRAWING
DIMENSIONS – P1 (METAL)
ITEM METRIC (mm) STANDARD (inch)
A 28.6 1.12
B 129.4 5.09
C 198.5 7.81
D 203.2 8
E 207.2 8.15
F 222.3 8.75
G 55.6 2.18
H 115.1 4.53
J 129.4 5.09
K 204.8 8.06
L 139.7 5.50
M 111.9 4.40
N 82.6 3.25
P 101.6 4
R 7.1 .28
S 30.2 1.18
T 30.2 1.18
BSP threads available.
SECTION 4B
DIMENSIONAL DRAWING
DIMENSIONS – P1 SANIFLOFDA (METAL)

A 204.0 8.03
B 48.4 1.93
C 131.8 5.18
D 220.7 8.68
E 53.2 2.09
F 115.1 4.53
G 124.6 4.90
H 258.0 10.15
J 115.9 4.56
K 229.4 9.03
L 142.9 5.62
M 113.5 4.46
N 82.6 3.25
P 101.6 4
R 7.1 .28

SECTION 5A
PERFORMANCE CURVES
Height ..............................222.3 mm (83⁄4")
Width ..............................207.2 mm (85⁄32")
Depth...............................204.8 mm (81⁄16")
Ship Weight ............Aluminum 6 kg (13 lbs.)
Stainless Steel 9.2 kg (20 lbs.)
Air Inlet ................................6.35 mm (1⁄4")
Inlet .......................................1.27 cm (1⁄2")
Outlet.....................................1.27 cm (1⁄2")
Suction Lift .....................5.79 m Dry (19')
9.45 m Wet (31')
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")
1
Displacement 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 psig) requires 4 Bar (60 psig) and
5.92 Nm3/h (3.5 scfm) air consumption.
(See dot on chart.) Flow rates indicated on chart were determined by pumping water.
Caution: Do not exceed 8.6 Bar (125 psig) air
supply pressure. For optimum life and performance, pumps should be specified so that daily operation
parameters will fall in the center of the pump performance curve.
SECTION 5B
PERFORMANCE CURVES
Height ..............................222.3 mm (83⁄4")
Width ..............................207.2 mm (85⁄32")
Depth...............................204.8 mm (81⁄16")
Air Inlet ................................6.35 mm (1⁄4")
Inlet .......................................1.27 cm (1⁄2")
Outlet.....................................1.27 cm (1⁄2")
9.45 m Wet (31')
Displacement per
Stroke ...................... .11 l (0.029 gal.)1
1
Bar (40 psig) requires 3.86 Bar (56 psig)
and 5.92 Nm3/h (3.5 scfm) air consump-
tion. (See dot on chart.) Flow rates indicated on chart were determined by pumping water.

SECTION 5C
PERFORMANCE CURVES
Height ..............................222.3 mm (83⁄4")
Width ..............................207.2 mm (85⁄32")
Depth...............................204.8 mm (81⁄16")
Air Inlet ................................6.35 mm (1⁄4")
Inlet .......................................1.27 cm (1⁄2")
Outlet.....................................1.27 cm (1⁄2")
9.45 m Wet (31')
Displacement per
Stroke ...................... .09 l (0.025 gal.)1
1
Bar (40 psig) requires 4 Bar (60 psig) and
5.92 Nm3/h (3.5 scfm) air consumption.
(See dot on chart.) Flow rates indicated on chart were determined by pumping water.
SECTION 6
SUCTION LIFT CURVES & DATA
These vacuum numbers will double when a small amount

of back pressure is placed on the discharge.
Suction lift curves are calibrated for pumps operating at 305 m viscosity of pumping fluid, elevation (atmospheric pressure) and
(1,000') above sea level. This chart is meant to be a guide only. pipe friction loss all affect the amount of suction lift your pump
There are many variables which can affect your pump’s operat- will attain.
ing characteristics. The number of intake and discharge elbows,

SECTION 7
INSTALLATION
The P1 Pro-Flo™ model has a 12.7 mm (1⁄2") inlet and 12.7 mm ELEVATION: Selecting a site that is well within the pump’s
(1⁄2") outlet and is designed for flows to 58.67 lpm (15.5 gpm). dynamic lift capability will assure that loss-of-prime troubles
Refer to Section 5 for performance characteristics. The P1 will be eliminated. In addition, pump efficiency can be
Metal pump is manufactured with wetted parts of Aluminum, adversely affected if proper attention is not given to site loca-
316 Stainless Steel, and Hastelloy. The P1 is available with a tion.
polypropylene or Acetal center section. A variety of
diaphragms, valve balls, valve seats and O-rings are available PIPING: Final determination of the pump site should not be
to satisfy temperature, chemical compatibility, abrasion and made until the piping problems of each possible location have
flex concerns. been evaluated. The impact of current and future installations
The suction pipe size should be at least 12.7 mm (1⁄2") diame- should be considered ahead of time to make sure that inad-
ter or larger if highly viscous material is being pumped. The vertent restrictions are not created for any remaining sites.
suction hose must be non-collapsible, reinforced type as the
P1 is capable of pulling a high vacuum. Discharge piping The best choice possible will be a site involving the shortest
should be at least 12.7 mm (1⁄2"); larger diameter can be used and straightest hook-up of suction and discharge piping.
to reduce friction losses. It is critical that all fittings and Unnecessary elbows, bends, and fittings should be avoided.
connections are airtight or a reduction or loss of pump suction Pipe sizes should be selected so as to keep friction losses
capability will result. within practical limits. All piping should be supported indepen-
dently of the pump. In addition, the piping should be aligned
INSTALLATION: Months of careful planning, study, and selec-
so as to avoid placing stress on the pump fittings.
tion efforts can result in unsatisfactory pump performance if
installation details are left to chance. Flexible hose can be installed to aid in absorbing the forces
created by the natural reciprocating action of the pump. If the
Premature failure and long term dissatisfaction can be
avoided if reasonable care is exercised throughout the instal- pump is to be bolted down to a solid location, a mounting pad
lation process. placed between the pump and the foundation will assist in
minimizing pump vibration. Flexible connections between the
LOCATION: Noise, safety, and other logistical factors usually pump and rigid piping will also assist in minimizing pump
dictate where equipment will be situated on the production vibration. If quick-closing valves are installed at any point in
floor. Multiple installations with conflicting requirements can the discharge system, or if pulsation within a system becomes
result in congestion of utility areas, leaving few choices for a problem, a surge suppressor should be installed to protect
additional pumps. the pump, piping and gauges from surges and water hammer.
Within the framework of these and other existing conditions, If the pump is to be used in a self-priming application, be sure
every pump should be located in such a way that five key factors that all connections are airtight and that the suction lift is within
are balanced against each other to maximum advantage. the model’s ability. Note: Materials of construction and elas-
tomer material have an effect on suction lift parameters.
ACCESS: First of all, the location should be accessible. If it’s Please refer to Section 6 for specifics.
easy to reach the pump, maintenance personnel will have an
The P1 can be installed in submersible applications only
easier time carrying out routine inspections and adjustments.
when both the wetted and non-wetted portions are compatible
Should major repairs become necessary, ease of access can
with the material being pumped. If the pump is to be used in a
play a key role in speeding the repair process and reducing
submersible application, a hose should be attached to the
total downtime.
pump’s air and pilot spool exhaust ports and piped above the
AIR SUPPLY: Every pump location should have an air line liquid level. The exhaust area for the pilot spool is designed to
large enough to supply the volume of air necessary to achieve be tapped with a 1⁄8" NPT fitting.
the desired pumping rate (see Section 5). Use air pressure up When pumps are installed in applications involving flooded
to a maximum of 8.6 Bar (125 psi) depending on pumping suction or suction head pressures, a gate valve should be
requirements. installed in the suction line to permit closing of the line for
For best results, the pumps should use a 5 micron air filter, pump service.
needle valve and regulator. The use of an air filter before the Pumps in service with a positive suction head are most effi-
pump will ensure that the majority of any pipeline contami- cient when inlet pressure is limited to 7–10 psig (.48–.68 Bar).
nants will be eliminated. Premature diaphragm failure may occur if positive suction is
When operation is controlled by a solenoid valve in the air line, .68 Bar (10 psig) and higher.
three-way valves should be used. This valve allows air THE MODEL P1 WILL PASS 1.6 MM (1⁄16") SOLIDS. WHEN-
trapped between the valve and the pump to bleed off which EVER THE POSSIBILITY EXISTS THAT LARGER SOLID
improves pump performance. Pumping volume can be deter- OBJECTS MAY BE SUCKED INTO THE PUMP, A STRAINER
mined by counting the number of strokes per minute and then SHOULD BE USED ON THE SUCTION LINE.
multiplying the figure by the displacement per stroke. CAUTION: DO NOT EXCEED 8.6 BAR (125 PSIG) AIR
MUFFLER: Sound levels are reduced below OSHA specifica- SUPPLY PRESSURE.
tions using the standard Wilden muffler. Other mufflers can be
used to further reduce sound levels, but they usually reduce
pump performance.

SUGGESTED INSTALLATION
AIR-OPERATED PUMPS: To stop the pump from

operating in an emergency situation, simply close
the “shut-off” valve (user supplied) installed in the
air supply line. A properly functioning valve will
stop the air supply to the pump, therefore
stopping output. This “shut-off” valve should be
located far enough away from the pumping
equipment such that it can be reached safely in
an emergency situation.
NOTE: In the event of a power failure, the shutoff
valve should be closed, if the restarting of the
pump is not desirable once power is regained.
SECTION 7B
SUGGESTED OPERATION AND
MAINTENANCE INSTRUCTIONS
OPERATION: Pump discharge rate can be controlled by limit- RECORDS: When service is required, a record should be
ing the volume and/or pressure of the air supply to the pump made of all necessary repairs and replacements. Over a
(preferred method). A regulator is used to regulate air pres- period of time, such records can become a valuable tool for
sure. A needle valve is used to regulate air volume. Pump predicting and preventing future maintenance problems and
discharge rate can also be controlled by throttling the pump unscheduled downtime. In addition, accurate records make it
discharge by partially closing a valve in the discharge line of possible to identify pumps that are poorly suited to their appli-
the pump. This action increases friction loss which reduces cations.
flow rate. This is useful when the need exists to control the
pump from a remote location. When the pump discharge pres- MAINTENANCE AND INSPECTIONS: Since each application
sure equals or exceeds the air supply pressure, the pump will is unique, maintenance schedules may be different for every
stop; no bypass or pressure relief valve is needed, and pump pump. Frequency of use, line pressure, viscosity and abra-
damage will not occur. The pump has reached a “deadhead” siveness of process fluid all affect the parts life of a Wilden
situation and can be restarted by reducing the fluid discharge pump. Periodic inspections have been found to offer the best
pressure or increasing the air inlet pressure. The Wilden P1 means for preventing unscheduled pump downtime. Person-
pump runs solely on compressed air and does not generate nel familiar with the pump’s construction and service should
heat, therefore your process fluid temperature will not be be informed of any abnormalities that are detected during
affected.
operation.

SECTION 7C
TROUBLESHOOTING
Pump will not run or runs slowly. 3. Check for sticking ball check valves. If material being
1. Ensure that the air inlet pressure is at least .35 Bar (5 psig) pumped is not compatible with pump elastomers, swelling may
above startup pressure and that the differential pressure (the occur. Replace ball check valves and seals with proper elas-
difference between air inlet and liquid discharge pressures) is tomers. Also, as the check valve balls wear out, they become
not less than .7 Bar (10 psig). smaller and can become stuck in the seats. In this case, replace
2. Check air inlet filter for debris (see recommended installa- balls and seats.
tion).
3. Check for extreme air leakage (blow by) which would indi- Pump air valve freezes.
cate worn seals/bores in the air valve, pilot spool, main shaft. 1. Check for excessive moisture in compressed air. Either
4. Disassemble pump and check for obstructions in the air install a dryer or hot air generator for compressed air. Alterna-
passageways or objects which would obstruct the movement of tively, a coalescing filter may be used to remove the water from
internal parts. the compressed air in some applications.
5. Check for sticking ball check valves. If material being
pumped is not compatible with pump elastomers, swelling may Air bubbles in pump discharge.
occur. Replace ball check valves and seals with proper elas- 1. Check for ruptured diaphragm.
tomers. Also, as the check valve balls wear out, they become 2. Check tightness of outer pistons (refer to Section 8C).
smaller and can become stuck in the seats. In this case, replace 3. Check tightness of clamp bands and integrity of O-rings
balls and seats. and seals, especially at intake manifold.
6. Check for broken inner piston which will cause the air valve 4. Ensure pipe connections are airtight.
spool to be unable to shift.
7. Remove plug from pilot spool exhaust. Product comes out air exhaust.
1. Check for diaphragm rupture.
Pump runs but little or no product flows. 2. Check tightness of outer pistons to shaft.
1. Check for pump cavitation; slow pump speed down to allow
thick material to flow into liquid chambers.
2. Verify that vacuum required to lift liquid is not greater than
the vapor pressure of the material being pumped (cavitation).

SECTION 8A
MODEL P1 METAL
DIRECTIONS FOR DISASSEMBLY/REASSEMBLY
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 pump. Disconnect all
intake, discharge, and air lines. Drain the pump by turning it
upside down and allowing any fluid to flow into a suitable
container. Be aware of any hazardous effects of contact with
your process fluid.
The Wilden model P1 has a 12.7 mm (1⁄2") inlet and outlet and is
designed for flows up to 58.67 lpm (15.5 gpm). The single-piece
center section, consisting of center block and air chambers, is
molded of acetal or polypropylene. All fasteners and hardware
are stainless steel and the air valve is manufactured of high-
tech engineered plastic. All O-rings used in the pump are of a
special material and shore hardness which should only be
replaced with factory-supplied parts.
TOOLS REQUIRED:
⁄8" Box Wrench
3
⁄16" Wrench
7
Adjustable Wrench DISASSEMBLY: Figure 1

Vise equipped with soft jaws (such as plywood, plastic
or other suitable material) Step 1.
Before starting disassembly, mark a line from each liquid cham-
NOTE: The model used for these instructions incorporates ber to its corresponding air chamber. This line will assist in
rubber diaphragms, balls, and seats. Models with Teflon® proper alignment during reassembly. (Figure 1)
diaphragms, balls and seats are the same except where noted.
Step 2. Figure 2 Step 3. Figure 3

Utilizing the 3⁄8" box wrench, start by removing the four long Remove the top manifold and lift the center section off the inlet
carriage bolts that hold the top and bottom manifolds to the manifold. (Figure 3)
center section. (Figure 2)

Remove the discharge valve balls, seats and O-rings from Inspect the ball retainer, retainer O-ring, and valve ball from
the discharge manifold and inspect for nicks, gouges, chem- intake manifold. Check for nicks, gouges, chemical attack or
ical attack or abrasive wear. Replace worn parts with abrasive wear. Replace worn parts with genuine Wilden parts
genuine Wilden parts for reliable performance. Teflon ® for reliable performance. Teflon® O-rings should be replaced
O-rings should be replaced when reassembled. (Figure 4) when reassembled. (Figure 5)
Step 6. Figure 6 Step 7. Figure 7 Step 8. Figure 8

Normally the inlet and discharge manifold Inspect O-rings for wear or damage and Use a 3⁄8" wrench to remove one set of
should not be disassembled during regular replace if necessary. Teflon® O-rings clamp bands that secure one liquid cham-
pump maintenance. Should this be neces- should be replaced when reassembled. ber to the one-piece center section.
sary, completely remove and disassemble (Figure 7) (Figure 8)
manifold clamp bands utilizing a 7⁄16"
wrench. (Figure 6)

Lift the liquid chamber away from the center section to expose Using an adjustable wrench, or by rotating the diaphragm by
the diaphragm and outer piston. (Figure 9) hand, remove the diaphragm assembly from the center section.
(Figure 10)
Step 11A. Figure 11A Step 11B. Figure 11B Step 12. Figure 12
NOTE: Due to varying torque values, one 2) The outer piston, diaphragm, inner To remove the diaphragm assembly from
of the following two situations may occur: piston, and disc spring separate from the the shaft, secure shaft with soft jaws (a
1) The outer piston, diaphragm and inner shaft which remains connected to the vise fitted with plywood or other suitable
piston remain attached to the shaft and the opposite side diaphragm assembly material) to ensure shaft is not nicked,
entire assembly can be removed from the (Figure 11B). Teflon®-fitted pumps come scratched, or gouged. Using an adjustable
center section. (Figure 11A) standard with back-up diaphragms (not wrench, remove diaphragm assembly
shown). from shaft. Inspect all parts for wear and
replace with genuine Wilden parts if
necessary. (Figure 12)

SECTION 8B
PRO-FLO™ AIR VALVE/CENTER SECTION
DISASSEMBLY, CLEANING, INSPECTION
AIR VALVE DISASSEMBLY:

CAUTION: Before any maintenance or repair is attempted,
the compressed air line to the pump should be discon-
nected and all air pressure allowed to bleed from the pump.
Disconnect all intake, discharge, and air lines. Drain the
pump by turning it upside down and allowing any fluid to
flow into a suitable container. Be aware of hazardous
effects of contact with your process fluid.
The Wilden Metal P1 utilizes a revolutionary Pro-Flo™ air
distribution system. A 1.27 cm (1⁄2") air inlet connects the air
supply to the center section. Proprietary composite seals
reduce the coefficient of friction and allow the P1 to run lube-
free. Constructed of Acetal or Polypropylene, the Pro-Flo™ air
distribution system is designed to perform in on/off, non-freez-
ing, non-stalling, tough duty applications.
TOOLS REQUIRED:
⁄16" Hex Head Wrench
3
⁄32" Hex Head Wrench

7
Snap Ring Pliers

O-Ring Pick
Step 1. Figure 1
Loosen the air valve bolts utilizing a ⁄16" hex head wrench.
3
(Figure 1)

Remove muffler plate and air valve bolts Lift away air valve assembly and remove Remove air valve end cap to expose air
from air valve assembly (Figure 2) expos- air valve gasket for inspection (Figure 3). valve spool by simply lifting up on end cap
ing muffler gasket for inspection. Replace Replace if necessary. once air valve bolts are removed.
if necessary. (Figure 4).

Remove air valve spool from air valve body by threading one air Remove pilot spool retaining snap ring on both sides of center
valve bolt into the end of the spool and gently sliding the spool section with snap ring pliers (Figure 6).
out of the air valve body (Figure 5). 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 sleeve from center With o-ring pick, gently remove the o-ring Check center section Glyd™ rings for
section (Figure 7). from the opposite side of the “center hole” signs of wear. If necessary, remove
cut on the spool. Gently remove the pilot Glyd™ rings with O-ring pick and replace.
spool from sleeve and inspect for nicks or (Figure 9)
gouges and other signs of wear. Replace
pilot sleeve assembly or outer sleeve o-
rings if necessary. During re-assembly
never insert the pilot spool into the sleeve
with the “center cut” side first, this end
incorporates the urethane o-ring and will
be damaged as it slides over the ports cut
in the sleeve.
NOTE: Seals should not be removed from
pilot spool.

SECTION 8C
REASSEMBLY HINTS & TIPS
ASSEMBLY:
Upon performing applicable maintenance to the air distribution
system, the pump can now be reassembled. Please refer to the
disassembly instructions for photos and parts placement. To
reassemble the pump, follow the disassembly instructions in
reverse order. The air distribution system needs to be assem-
bled first, then the diaphragms and finally the wetted path.
Please find the applicable torque specifications on this page.
The following tips will assist in the assembly process.
• Clean the inside of the center section shaft bore to ensure
no damage is done to new seals.
• Stainless bolts should be lubed to reduce the possibility of
seizing during tightening.
• Level the water chamber side of the intake/discharge mani-
fold to ensure a proper sealing surface. This is most easily
accomplished by placing them on a flat surface prior to tight-
ening their clamp bands to the desired torque (see this page
for torque specs).
• Be sure to tighten outer pistons simultaneously on Teflon®-
fitted pumps to ensure proper torque values.
• Ensure proper mating of liquid chambers to manifolds prior
to tightening vertical bolts. Overhang should be equal on
both sides.
• Apply a small amount of Loctite 242 to the shaft interval
threads before the diaphragm assembly.
• Concave side of disc spring in diaphragm assembly faces
toward shaft.
MAXIMUM TORQUE SPECIFICATIONS

Description of Part Metal Pumps
Air Valve, Pro-Flo™ 2.8 m-N [25 in.-lbs.]
Outer Piston 10.2 m-N [90 in.-lbs.]
Small Clamp Band 1.7 m-N [15 in.-lbs.]
Large Clamp Band (Rubber-Fitted) 7.4 m-N [65 in.-lbs.]
Large Clamp Band (Teflon®-Fitted) 9.6 m-N [85 in.-lbs.]
Vertical Bolts 14.1 m-N [125 in.-lbs.]
Air Inlet, Reducer Bushing 13.6 m-N [10 ft.-lbs.]

SECTION 9A
EXPLODED VIEW/PARTS LISTING
P1
METAL
AIR-
CONTROLLED
RUBBER/TPE-
FITTED

MODEL P1 METAL RUBBER-FITTED
Qty. P1/ P1/ P1/ P1/
Per APPP SPPP HPPP SPPP/070
Item Part Description Pump P/N P/N P/N P/N
1 Pro-Flo™ Air Valve Assembly1 1 01-2010-20 01-2010-20 01-2010-20 01-2010-20
2 End Cap 1 01-2332-20 01-2332-20 01-2332-20 01-2332-20
3 O-Ring, End Cap 1 01-2395-52 01-2395-52 01-2395-52 01-2395-52
4 Gasket, Air Valve 1 01-2615-52 01-2615-52 01-2615-52 01-2615-52
5 Screw, HSHC, Air Valve 1⁄4-20 4 01-6001-03 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 04-6400-03
7 Center Section Assembly 1 01-3140-20 01-3140-20 01-3140-20 01-3140-20
8 Bushing, Reducer 1 01-6950-20 01-6950-20 01-6950-20 01-6950-20
9 Removable Pilot Sleeve Assembly 1 01-3880-99 01-3880-99 01-3880-99 01-3880-99
10 Glyd™ Ring II 2 01-3220-55 01-3220-55 01-3220-55 01-3220-55
11 Retaining Ring 2 00-2650-03 00-2650-03 00-2650-03 00-2650-03
12 Muffler Plate 1 01-3181-20 01-3181-20 01-3181-20 01-3181-20
13 Gasket, Muffler Plate 1 01-3505-52 01-3505-52 01-3505-52 01-3505-52
14 Muffler 1 02-3510-99 02-3510-99 02-3510-99 02-3510-99
15 Shaft, Pro-Flo™ 1 01-3810-03 01-3810-03 01-3810-03 01-3810-03
16 Disc Spring 2 01-6802-08 01-6802-08 01-6802-08 01-6802-08
17 Inner Piston 2 01-3711-08 01-3711-08 01-3711-08 01-3711-08
18 Outer Piston 2 01-4570-01 01-4570-03 01-4570-04 01-4570-03
19 Liquid Chamber 2 01-5000-01 01-5000-03 01-5000-04 01-5000-03
20 Manifold Tee Section 2 01-5160-01 01-5160-03 01-5160-04 01-5160-03-70
21 Inlet Manifold Elbow 2 01-5220-01 01-5220-03 01-5220-04 01-5220-03
22 Discharge Manifold Elbow 2 01-5230-01 01-5230-03 01-5230-04 01-5230-03
23 Screw, SHCS (Chamber Bolt) 4 01-6080-03 01-6080-03 01-6080-03 01-6080-03
24 Vertical Bolt Washer 4 01-6730-03 01-6730-03 01-6730-03 01-6730-03
25 Vertical Bolt Nut 4 04-6400-03 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 * * * 01-1120-03
29 Valve Seat O-Ring 4 * * * 01-1200-56
30 Manifold O-Ring 4 * * * 01-1300-56
31 Small Clamp Band Assy. 4 01-7100-03 01-7100-03 01-7100-03 01-7100-03
32 Small Clamp Band Bolt 8 01-6101-03 01-6101-03 01-6101-03 01-6101-03
33 Small Clamp Band Nut 8 01-6400-03 01-6400-03 01-6400-03 01-6400-03
34 Large Clamp Band Assy. 2 01-7300-03 01-7300-03 01-7300-03 01-7300-03
35 Large Clamp Band Bolt 4 01-6070-03 01-6070-03 01-6070-03 01-6070-03
36 Large Clamp Band Nut 4 04-6400-03 04-6400-03 04-6400-03 04-6650-03-70
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.

SECTION 9B
EXPLODED VIEW/PARTS LISTING
P1
METAL
AIR-
CONTROLLED
TEFLON®-
FITTED

MODEL P1 METAL TEFLON®-FITTED
Qty. P1/ P1/ P1/ P1/
Per APPP SPPP HPPP SPPP/070
Item Part Description Pump P/N P/N P/N P/N
1 Pro-Flo™ Air Valve Assembly1 1 01-2010-20 01-2010-20 01-2010-20 01-2010-20
2 End Cap 1 01-2332-20 01-2332-20 01-2332-20 01-2332-20
3 O-Ring, End Cap 1 01-2395-52 01-2395-52 01-2395-52 01-2395-52
4 Gasket, Air Valve 1 01-2615-52 01-2615-52 01-2615-52 01-2615-52
5 Screw, HSHC, Air Valve 1⁄4-20 4 01-6001-03 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 04-6400-03
7 Center Section Assembly 1 01-3140-20 01-3140-20 01-3140-20 01-3140-20
8 Bushing, Reducer 1 01-6950-20 01-6950-20 01-6950-20 01-6950-20
9 Removable Pilot Sleeve Assembly 1 01-3880-99 01-3880-99 01-3880-99 01-3880-99
10 Glyd™ Ring II 2 01-3220-55 01-3220-55 01-3220-55 01-3220-55
11 Retaining Ring 2 00-2650-03 00-2650-03 00-2650-03 00-2650-03
12 Muffler Plate 1 01-3181-20 01-3181-20 01-3181-20 01-3181-20
13 Gasket, Muffler Plate 1 01-3505-52 01-3505-52 01-3505-52 01-3505-52
14 Muffler 1 02-3510-99 02-3510-99 02-3510-99 01-3510-99
15 Shaft, Pro-Flo™ 1 01-3810-03 01-3810-03 01-3810-03 01-3810-03
16 Disc Spring (Belleville Washer) 2 01-6802-08 01-6802-08 01-6802-08 01-6802-08
17 Inner Piston 2 01-3711-08 01-3711-08 01-3711-08 01-3711-08
18 Outer Piston 2 01-4570-01 01-4570-03 01-4570-04 01-4570-03
19 Liquid Chamber 2 01-5000-01 01-5000-03 01-5000-04 01-5000-03
20 Manifold Tee Section 2 01-5160-01 01-5160-03 01-5160-04 01-5160-03-70
21 Inlet Manifold Elbow 2 01-5220-01 01-5220-03 01-5220-04 01-5220-03
22 Discharge Manifold Elbow 2 01-5230-01 01-5230-03 01-5230-04 01-5230-03
23 Screw, SHCS (Chamber Bolt) 4 01-6080-03 01-6080-03 01-6080-03 01-6080-03
24 Vertical Bolt Washer 4 01-6730-03 01-6730-03 01-6730-03 01-6730-03
25 Vertical Bolt Nut 4 04-6400-03 04-6400-03 04-6400-03 04-6650-03-70
26 PTFE Primary Diaphragm 2 01-1010-55 01-1010-55 01-1010-55 01-1010-55
27 Neoprene Backup Diaphragm 2 01-1060-51 01-1060-51 01-1060-51 01-1060-51
28 Valve Ball 4 01-1080-55 01-1080-55 01-1080-55 01-1080-55
29 Valve Seat 4 01-1120-01 01-1120-03 01-1120-04 01-1120-03
30 Valve Seat O-Ring 4 01-1200-55 01-1200-55 01-1200-55 01-1200-55
31 Manifold O-Ring 4 01-1300-55 01-1300-55 01-1300-55 01-1300-55
32 Small Clamp Band Assy. 4 01-7100-03 01-7100-03 01-7100-03 01-7100-03
33 Small Clamp Band Bolt 8 01-6101-03 01-6101-03 01-6101-03 01-6101-03
34 Small Clamp Band Nut 8 01-6400-03 01-6400-03 01-6400-03 01-6400-03
35 Large Clamp Band Assy. 2 01-7300-03 01-7300-03 01-7300-03 01-7300-03
36 Large Clamp Band Bolt 4 01-6070-03 01-6070-03 01-6070-03 01-6070-03
37 Large Clamp Band Nut 4 04-6400-03 04-6400-03 04-6400-03 04-6650-03-70
1
*Refer to corresponding elastomer chart in Section 10.
070 Specialty Code = SanifloFDA

SECTION 10A
ELASTOMER OPTIONS
ELASTOMER OPTIONS FOR MODEL P1 METAL PUMPS
Diaphragm Valve Ball Valve Seat Valve Seat O-Ring Manifold O-Ring
Material P/N P/N P/N P/N P/N
Polyurethane 01-1010-50 01-1080-50 N/A 01-1200-50 01-1300-50
Buna-N 01-1010-52 01-1080-52 N/A 00-1260-52 01-1300-52
Viton® 01-1010-53 01-1080-53 N/A N/A N/A
Wil-Flex™ 01-1010-58 01-1080-58 N/A 00-1260-58 01-1300-58
Saniflex™ 01-1010-56 01-1080-56 N/A 01-1200-56 01-1300-56
Teflon PTFE
®
01-1010-55 01-1080-55 N/A 01-1200-55 01-1300-55
Stainless Steel N/A N/A 01-1120-03 N/A N/A
Aluminum N/A N/A 01-1120-01 N/A N/A
Hastelloy N/A N/A 01-1120-04 N/A N/A

MAINTENANCE RECORD
DATE SERVICE RENDERED SERVICED BY
WILDEN PUMP & ENGINEERING CO.

7 Filters
Filter
7.1 Y-Strainer
Schmutzfänger
Type 22.050
7.2 Air Cleaner
Nassluftfilter

Operating and installation instructions
Strainer
Contents
1.0 General information on operating 6.0 Putting the valve into operation ..................6
instructions ................................................... 2 7.0 Care and maintenance..................................6
2.0 Notes on possible dangers.......................... 2 8.0 Troubleshooting ............................................7
2.1 Significance of symbols ........................................2 9.0 Troubleshooting table ..................................7
2.2 Explanatory notes on safety information ...............2 10.0 Dismantling the valve or the top part .......8
3.0 Storage and transport ................................. 2 11.0 Warranty / Guarantee ..................................8
4.0 Description .................................................... 3 12.0 EC declaration of conformity .....................9
4.1 Scope of applications ............................................3
4.2 Operating principles ..............................................3
4.3 Diagram.................................................................4
4.4 Technical data - remarks .......................................4
4.5 Marking .................................................................5
5.0 Installation..................................................... 5
5.1 General notes on installation.................................5
5.2 Installing valves with butt weld ends .....................6
Rev. 0040101000 2103 englisch

Strainer
1.0 General information on operating instructions

These operating instructions provide information on mounting and maintaining the fittings.
Please contact the supplier or the manufacturer in case of problems which cannot be
solved by reference to the operating instructions.
They are binding on the transport, storage, installation, start-up, operation, maintenance
and repair.
The notes and warnings must be observed and adhered to.
- Handling and all work must be carried out by expert personnel or all activities must be
supervised and checked.
It is the owner’s responsibility to define areas of responsibility and competence and to
monitor the personnel.
- In addition, current regional safety requirements must be applied and observed when
taking the fittings out of service as well as when maintaining and repairing them.
The manufacturer reserves the right to introduce technical modifications at any time.
These Operating Instructions comply with the requirements of EU Directives.
2.0 Notes on possible dangers
2.1 Significance of symbols
ATTENTION !
... Warning of general danger.
2.2 Explanatory notes on safety information

In these Operating and Installation Instructions dangers, risks and items of safety
information are highlighted to attract special attention.
Information marked with the above symbol and “ATTENTION ! ” describe practices, a
failure to comply with which can result in serious injury or danger of death for users or third
parties or in material damage to the system or the environment. It is vital to comply with
these practices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operating
and maintenance instructions as well as technical data (in the operating instructions,
product documentation and on the device itself) must also be complied with to the fullest
extent in order to avoid faults which in turn can cause serious injury to persons or damage
to property.
3.0 Storage and transport

ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- Valve mountings such as actuators, handwheels, hoods must not be used to
take external forces, e.g. they are not designed for use as climbing aids, or as
connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.
See catalog sheet for weights.
- At -20°C to +65°C.
- The paint is a base coat to protect against corrosion during transportation and storage. Do
not damage paint protection.
Page 2 Rev. 0040101000 2103

Strainer
4.0 Description
4.1 Scope of applications
Strainers are used for "cleanin flowing mediums“.
ATTENTION !
- Refer to the data sheet for applications, limits on use and possibilities.
- Certain media require or preclude the use of special materials.
- The valves are designed for standard operating conditions. If conditions exceed
these requirements, e.g. aggressive or abrasive media, the operator should
state the higher requirements when ordering.
- Valves made from grey cast iron are not authorised for use in systems subject
to TRD 110.
The information complies to the Pressure Equipment Directive 97/23/EC.
It is the responsibility of the machine planner to ensure compliance.
The special markings on the valve must be taken into account.
Refer to the catalogue sheet to see which materials are used in standard versions.
Please contact the supplier or the manufacturer if you have any questions.
4.2 Operating principles

The medium flows through the strainer screen in the direction shown on the strainer and is
thereby cleaned.
Rev. 0040101000 2103 Page 3

Strainer
4.3 Diagram
rotated
rotated view
view
fig. 1: Strainer - Y fig. 2: Strainer - Y SE
rotated
view
fig. 3: Strainer - Y (1.4408)

Refer to the data sheet for information about materials with designations and figure
numbers.
4.4 Technical data - remarks

for
- Principal dimensions
- Pressure-temperature-ratings
- Valves with butt weld ends, etc. refer to datasheet.
Page 4 Rev. 0040101000 2103

Strainer
4.5 Marking
Details of the CE-marking on the valve:
CE-marking
0525 Notified body
Manufacturer Address of manufacturer:
Typ Type refer to item 11.0 Warranty / Guarantee
Bj. Year of manufacture
According to the Pressure Equipment Directive table 6, annex II, valves without safety
function are only allowed to bear the CE-marking DN32 onwards.
5.0 Installation
5.1 General notes on installation
The following points should be taken into account besides the general principles governing
installation work:
ATTENTION !
- Remove flange covers if present.
- The interior of valve and pipeline must be free from foreign particles.
- Note installation position with reference to flow direction, see mark on valve.
- Steam line systems should be designed to prevent water accumulation.
- Lay pipelines so that damaging transverse, bending and torsional forces are
avoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
See data sheet for weights.
- Leave sufficient space to remove the screen basket during installation in
pipelines.
- Installation position:
a) The screen basket should never be at the top, otherwise the dirt will
fall back into the pipe.
b) If water hammer is possible due to condensation in steam lines,
never install the trap with the screen basket at the bottom, but install
it so that it is horizontal.
- Centre gaskets between the flanges.
- Install compensators to compensate for thermal expansion of the piping.
- Planners / construction companies or operators are responsible for positioning and

installing products.
Rev. 0040101000 2103 Page 5

Strainer
5.2 Installing valves with butt weld ends
Please note that only qualified persons using appropriate equipment and working in
accordance with technical rules are allowed to install fittings by welding.
The responsibility for this lies with the system owner.
Refer to the data sheet for information about the shape of the butt weld ends.
6.0 Putting the valve into operation
ATTENTION !
- Before putting the valve into operation, check material, pressure, temperature
and direction of flow.
- Regional safety instructions must be adhered to.
- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
- Touching the valve when it is operating at high (> 50°C) or low (< 0°C) media
temperatures can cause injury.
Affix warning notice or protective insulation as appropriate!
Before putting a new plant into operation or restarting a plant after repairs or
modification, always make sure that:
- All works has been completed!
- The valve is in the correct position for its function.
- Safety devices have been attached.
7.0 Care and maintenance

The strainer screens must be cleaned regularly. Maintenance and maintenance-intervals
have to be defined by the operator and depends on the degree of dirt accumulation in the
system.
- If necessary, the strainer can be fitted with an additional start-up filter (e.g. filter with
supporting basket) to start up the system.
- Flush the plant thoroughly before starting it.
- The strainer requires little maintenance.
ATTENTION !
Refer to point 10.0 before opening the strainer.
- Contaminated strainers in suction-lines will result cavitation and damage the
pumps.
- Before reassembling the unit, remember that the bearing surface must be cleaned and a
new gasket (pos. 6) must be inserted.
- Set the strainer cover (pos. 2) in place.
- Tighten the hexagon nuts (pos. 4) evenly crosswise.
Page 6 Rev. 0040101000 2103

Strainer
Tightening torque‘s for hexagon nuts / bolts:
hexagon nuts / Torque
DN
bolts (Nm)
15- 32 M 10 20-35
40 M 12 20-35
50- 65 M 12 60-80
80-150 M 16 100-125
200 M 20 150-200
250-400 M 24 340-410
500 M 27 340-410
8.0 Troubleshooting
In the event of malfunction or faulty operating performance check that the installation and
adjustment work has been carried out and completed in accordance with these Operating
Instructions.
ATTENTION !
-
It is essential that the safety regulations are observed when identifying faults.
If malfunctions cannot be eliminate with the help of the following table

“9.0 troubleshooting table”, the supplier or manufacturer should be consulted.
9.0 Troubleshooting table

ATTENTION !
- read point 10.0 and 11.0 prior to dismantling and repair work!
- read point 6.0 before restarting the plant !
Fault Possible cause Corrective measures

No flow Flange covers have not been removed Remove flange covers
(7, Fig. 3, page 4) (7, Fig. 3, page 4)
Flow too low strainer clogged. Clean/replace screen.
Piping clogged. Check piping system.
Flange broken between Bolts tightened unevenly. Re-align piping and fit new valve!
unit and piping Mating flanges not properly aligned.
Rev. 0040101000 2103 Page 7

Strainer
10.0 Dismantling the valve or the top part

ATTENTION !
The following points must be observed:
- Pressureless pipe system.
- Medium must be cool.
- Plant must be drained.
- Purge piping systems in case of caustic, inflammable, aggressive or toxic
media.
11.0 Warranty / Guarantee

The extent and period of warranty cover are specified in the "Standard Terms and
Conditions of Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of
departure, in the contract of sale itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and the
confirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handling
or disregard of operating and installation instructions, datasheets and relavant regulations.
This warranty also does not cover any damage which occurs during operation under
conditions deviating from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialist
appointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacement
delivery is excluded.
The warranty shall not cover maintenance work, installation of external parts, design
modifications or natural wear.
Any damage incurred during transport should not be reported to us but rather to the
competent cargo-handling depot, the railway company or carrier company immediately or
else claims for replacements from these companies will be invalidated.
Technology for the Future.

GERMAN QUALITY VALVES
ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schloß Holte-Stukenbrock
Telephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159
Internet: http://www.ari-armaturen.com E-mail: info.vertrieb@ari-armaturen.com
Page 8 Rev. 0040101000 2103

Strainer
12.0 EC declaration of conformity

ARI-Armaturen Albert Richter GmbH & Co. KG,
Mergelheide 56-60, D-33756 Schloß Holte-Stukenbrock
EC declaration of conformity
as defined by
the Pressure Equipment Directive 97/23/EC
Herewith we declare,
that according to the above mentioned Pressure Equipment Directive (PED) the below
listed products comply and have been approved according to table 6, annex II, Module H
through LLOYD´S REGISTER QUALITY ASSURANCE (BS-Nr. 0525), Mönckebergstr. 27,
D-20095 Hamburg.
Certificate-No: 50003/1
Strainers
Type 050, 059, 080
Applied standards:
DIN 3230
DIN 3840
AD 2000 leaflet A4
- Cast iron with spheroidal graphite
- Cast steel
- Forged steel
Schloß Holte-Stukenbrock, 20.08.2002
...................................................
(Brechmann, Managing director)
Rev. 0040101000 2103 Page 9

MANN Oil wetted air cleaners
Applications Service
MANN Oil wetted air cleaners are suitable for When dust becomes clearly visible on the filter,
filtering intake air for machinery operated in wash it out with diesel fuel. After washing, shake
relatively clean air, e.g. stationary engines and off the excess fuel well. Oil wetted air cleaners
compressors in closed rooms, on marine engines may also be cleaned with a steam jet cleaner.
etc.
After cleaning, apply an even, thin layer of engine
oil to the filter packing (if dipped in an oil bath,
Design and principle of operation shake off the excess oil afterwards).
The air drawn in through an oil wetted air cleaner
flows through a packing wetted with oil and Neglected filter service leads to a definite impair-
made of expanded metal or knitted steel mesh. ment of the filter action, and thus to premature
Dust particles are deposited on the oil-wetted wear of the assemblies connected downstream
surface of the filter packing. from the filter.
MANN Oil wetted air cleaners for stack connec-

tions are available in cylindrical shapes for
mounting vertically (page 53).
The silencer version is especially suitable for

compressors in closed rooms (Fig. 1 and 2/page
54).
Dimensioning and installation

Filters must be positioned in such a way that
extracted dust cannot be shaken back onto
their clean side.
Silencers may be installed horizontally to

vertically face down. A deviation of 15° is per-
missible. Filters must be adequately shielded
from rain and any water spray.
The filter size is determined by its nominal flow

rate. If a larger filter can be installed (one with a
normal flow rate larger than the amount of air
required), it improves the filter effectiveness,
increases the dust capacity and extends the
filter’s service life.
52
Dimensions and
Dimensions, part flow characteristics
numbers and flow characteristics
d2
h1
h2
Filter as per DIN 73 353
d1
Part No. Nominal flow Dimensions in mm Weight

rate1) approx.
[m3/min] [kg]
d1 d2 h1 h2
43 014 67 012 1.4 30 80 78 32 0.25
43 018 67 012 1.8 35 80 90 32 0.4
43 018 67 022 1.8 40 80 90 32 0.3
43 036 67 012 3.6 52 107 110 32 0.6
43 046 67 012 4.6 60 107 128 34 0.8
43 060 67 012 6 66 120 140 35 1.0
43 080 67 102 8 70 120 175 35 1.2
43 100 67 012 10 80 147 180 38 1.5
43 130 67 012 13 100 147 215 38 1.8
43 180 67 012 18 120 166 250 38 2.5
43 240 67 012 24 150 196 285 50 3.3
43 320 67 012 32 200 232 330 45 5.4
43 870 67 102 87 300 340 640 95 16.0
1) Nominal flow rate based on approx. 15 mbar.
Flow characteristics for the flow rate as per ISO 5011
20
Flow resistance ∆ p [mbar]
10
9
8
2
2
012
012
012
012
7
7 02
7 01
7 01
7 01
7 01
7 10
7 01
7 01
7 10
6 67
0 67
0 67
7
18 6
14 6
18 6
36 6
60 6
80 6
80 6
40 6
20 6
70 6
6
4
3
43 0
43 0
43 0
43 0
43 0
43 0
43 0
43 1
43 1
43 1
43 2
43 3
43 8
2
0.5 0.6 0.8 1 2 4 6 8 10 20 40 60 80 100
.
Volume flow V [m3/min]
53
8 Heat Exchanger
Wärmetauscher
8.1 Plate Heat Exchanger

Plattenwärmetauscher
Type OC4

Gelötete Plattenwärmetauscher / Brazed Plate Heat Exchanger /
Echangeurs de chaleur à plaques brasées
Montage-, Betriebs- und Wartungsanleitung

Installation and Application Guide
Instructions de montage, d’installation et d‘entretien
Achtung:
Lesen Sie diese Anleitung vor Montage und Inbetriebnahme sorgfältig durch. Gewährleistungsansprüche
entfallen, soweit die Montage-, Betriebs- und Wartungsanleitung nicht beachtet wird.
Prüfen Sie bitte bei der Anlieferung, ob Beschädigungen vorhanden sind bzw. ob Teile fehlen. Vermerken
Sie entsprechendes auf den Speditionspapieren.
GEA WTT gelötete Plattenwärmetauscher haben scharfe Kanten. Bitte beachten Sie dieses bei der
Handhabung.
Attention:
Before proceeding with installation and operation please read entire guide carefully. Failure to do so can
cause injury or property damage.
When receiving heat exchangers, any claims for damage or shortage of parts in shipment must be filed
immediately against the transportation company by the consignee.
GEA WTT heat exchangers may have some sharp edges so please handle with care.
Attention:
Ces instructions sont à lire avec soin avant le montage et la mise en service de l’échangeur. Si ces
instructions ne sont pas suivies, nous ne pouvons donner suite à une éventuelle demande de garantie.
Contrôler dès réception si l’échangeur de chaleur présente des dommages ou bien si des pièces
manquent. Dans ce cas, faire les remarques appropriées sur les bordereaux du transporteur.
Les échangeurs de chaleur peuvent avoir des arêtes coupantes. Maniez-les avec prudence.
GEA WTT GmbH

Remsaer Straße 2a, 04603 Nobitz - Wilchwitz, Deutschland
Tel. +49 3447 55 39 0, www.gea-phe.com
Jena HRB 202818, ID-No. DE 150 539 388, Steuernr.: 306/5708/5007
Geschäftsführung: Andreas Dunkel, Dirk-André Schenk
Bankverbindung: Deutsche Bank AG Frankfurt; BLZ 500 700 10, S.W.I.F.T. Code DEUTDEFF, KTO 0 942 011 00, IBAN DE08 5007 0010 0094 2011 00
Inhaltsverzeichnis
Beschreibung / Konformitätserklärung 1
Montageposition 2
Anschluss an das Rohrnetz 3
Lötanschluss, Schweißanschluss, Gewindeanschluss 4
Inbetriebnahme 5
Betrieb 6
Frostschutz 6
Verschmutzung / Fouling 7
Reinigung 7
Korrosionsbeständigkeit von gelöteten Plattenwärmetauschern gegenüber Wasserinhaltsstoffen 8
Volumenangaben 10
Montageanleitung Isolierungen 11
Montageanleitung Verteilerrohre 12
Table of contents
Description / Declaration of Conformity 1

Mounting position 2
Piping connections 3
Soldering, welding, threading connections 4
Start of operation 5
Operation 6
Anti-freeze 6
Fouling 7
Cleaning 7
Corrosion resistance of soldered plate heat exchangers compared to water constituents 8
Volume of brazed plate heat exchangers 10
Fitting instructions for insulation 11
Fitting instructions for distributing pipes 12
Sommaire
Description / Déclaration de Conformité 1

Montage 2
Raccordement au système de tuyauteries 3
Raccords brasés, soudés, filetés 4
Mise en service 5
Fonctionnement 6
Protection antigel 6
Encrassement 7
Nettoyage 7
Résistance à la corrosion 8
Volume des échangeurs de chaleur à plaques brasées 10
Instructions de montage des isolations 11
Instructions de montage des échangeurs de chaleur à plaques brasées munis d’un distributeur 12
GEA WTT GmbH

Beschreibung / Konformitätserklärung
GEA WTT gelötete Plattenwärmetauscher bestehen aus einer Anzahl geprägter Edelstahlplatten, die in einem speziellen Lötverfahren
mittels Kupfer oder Nickel miteinander verbunden werden. Beim Zusammenfügen wird jede zweite Platte um 180 Grad in der Ebene
gedreht, wodurch sich zwei voneinander getrennte Strömungsräume bzw. Druckräume (Primär- und Sekundärseite) bilden.
Konformitätserklärung: siehe Homepage www.gea-phe.com; News & Downloads
Werkstoffe:
Platten: Edelstahl 1.4401/1.4404 - SA240 316/SA240 316L (Standard)
Edelstahl 1.4547 / SA240 S 31254 (XCR-Modelle, WP7M-40-XCR)
Lot: Kupfer (Typ GBE…, GBS…, GBH..., WP..., WH…, DW...)

Nickel (Typ GNS…, NP...)
Angaben zum Typ, Baujahr, Herstellernummer, Hersteller sowie die technischen Daten sind dem Typenschild zu entnehmen. Es sind
geeignete Maßnahmen zu treffen, damit die angegebenen zulässigen max. und min. Betriebsparameter weder im Betrieb noch im Stillstand
über- bzw. unterschritten werden.
Bitte beachten Sie die Angaben auf dem Typenschild des Wärmetauschers!
GEA WTT gelötete Plattenwärmetauscher sind Druckgeräte im Sinne der Richtlinie über Druckgeräte 97/23/EG. Die EG-Baumusterprüfung
(Modul B) und die Bewertung des QS Systems (Modul D) erfolgten durch die benannte Stelle:
TÜV Thüringen e.V. - Melchendorfer Str. 64 - DE – 99096 Erfurt
Registrier-Nr. der benannten Stelle: 0090
Description / Declaration of Conformity

GEA WTT brazed plate heat exchangers consist of a pack of embossed steel plates which are brazed together by copper or nickel in a
furnace. When assembling the pack every second plate is turned 180° in the plane. There are two separate flow channels or pressure
channels (Primary and Secondary Side) with two mediums in counter current.
Declaration of Conformity: see homepage www.gea-phe.com; News & Downloads
Materials:
Plates: Stainless steel 1.4401/1.4404 - SA240 316/SA240 316L (Standard)
Stainless steel 1.4547 / SA240 S 31254 (XCR-models)
Solder: Copper (Type GBE…, GBS…, GBH..., WP..., WH…, DW...)

Nickel (Type GNS..., NP…)
Details on the type, year of construction, serial number, manufacturer as well as technical data have to be taken from the nameplate of the
heat exchanger. Suitable measures have to be taken so that the given permitted max. and min. technical data neither in operation or in
interruption are shouted down or falls exceed.
Please note the data on the nameplate of the heat exchanger!
GEA WTT heat exchangers are pressure equipment according to the Pressure Equipment Directive 97/23/EC. Notified body for the EC
inspection (module B) and the evaluation of quality assurance system (module D) is:
Registration No. of the Notified Body : 0090
Description / Déclaration de conformité

Les échangeurs de chaleur à plaques brasées GEA WTT sont constitués d’un empilage de plaques corruguées en acier inox, l’étanchéité
étant assurée par un procédé spécial de brasage au cuivre ou au nickel. A l’empilage, une plaque sur deux est inversée à 180 degrés afin
de créer deux zones de circulation séparées.
Déclaration de Conformité: voir page d'accueil www.gea-phe.com; News et téléchargements
Matériaux:
Plaques: Acier inox. 1.4401/1.4404 - SA240 316/SA240 316L
Acier inox. 1.4547 / SA240 S 31254 (modèle XCR)
Brasure: au Cuivre (GBE…, GBS…, GBH..., WP..., WH…, DW...)

au Nickel (Type GNS…, NP…)
Le modèle, l’année de fabrication, le no. de série, le fabricant ainsi que les données techniques sont indiqués sur la plaque signalétique.
Veillez à prendre les mesures adéquates afin que les paramètres techniques de service indiqués soient respectés tant en fonctionnement
que pendant les arrêts.
Prière de tenir compte des indications données sur la plaque signalétique de l’échangeur !
Les échangeurs de chaleur à plaques brasées sont des appareils sous pression conformément à la circulaire 97/23/EG. Le dépôt des
modèles EG (module B) et l’examen du QS System (Module D) ont été effectués auprès du :
Enregistrement No.: 0090
-1- GEA WTT GmbH

Empfohlene Montageposition: Senkrecht Montageposition
Recommended mounting position: Vertical GEA WTT gelötete Plattenwärmetauscher sollten so montiert
Position de montage recommandée: Verticale werden, dass ausreichend Platz vorhanden ist, um
Wartungsaufgaben zu erfüllen. Die Einbaulage ist so zu wählen,
dass die Entlüftung und die Entleerung des Wärmetauschers
möglich sind. Bei wärmetechnischen Anwendungen ist die
senkrechte Einbaulage am effizientesten. Alle anderen Einbaulagen
können zu Leistungsverlusten führen. Kältetechnische
Anwendungen, wie Verdampfer- oder Kondensatoranlagen,
verlangen stets eine senkrechte Einbaulage.
Niemals den Wärmetauscher mit den Anschlüssen nach unten
montieren. Vorsorglich sollten die Wärmetauscher an einer Konsole
befestigt werden. Eine Halterung nur an den Anschlüssen ist nicht
ausreichend.
Die max. Anschlusskräfte und -momente nicht überschreiten.
Mounting position
GEA WTT heat exchangers should be mounted so there is
sufficient room around the heat exchanger to perform maintenance
work. The fitting position is to be chosen in such a way that venting
and draining of the heat exchanger are possible.
For thermal applications a vertical fitting position is the most
efficient one. All other fitting positions can lead to power loss.
For all two phase applications the heat exchanger should always be
mounted vertically (Evaporator, condenser...).
Never mount the heat exchanger with the connections pointing
down. Preferably the heat exchanger should be supported by a
bracket or support. The unit should not be supported solely by the
piping.
The maximum connecting forces and torques are not to be
exceeded.
Montage
Les échangeurs GEA WTT doivent être montés de façon à laisser
assez de place pour assurer les travaux d’entretien. La position de
montage doit permettre la purge de l’air et la vidange de
l’échangeur. Pour les applications de chauffage, l‘échangeur de
chaleur peut être monté en toute position. A noter toutefois que
seule la position verticale assure un rendement maximum, toute
autre position pouvant provoquer des pertes de rendement.
Lorsque l’échangeur est utilisé dans des applications diphasiques
(évaporateur, condenseur…) seule la position verticale est
admissible.
Ne jamais installer l’échangeur de chaleur avec les raccordements
tournés vers le bas. Il est recommandé de fixer l’échangeur sur un
support. Une fixation uniquement par les raccords n’est pas
suffisante.
Ne dépasser en aucun cas les couples de serrage admissibles.
Maximale Anschlusskräfte und Momente

Maximum fitting forces and torques
Couples de serrage admissibles:
BPHE Anschluss T F Mb Mv
GB…; WP…; Connection (kN) (kN) (Nm) (Nm)
NP…; GNS…; Raccord
DW…
1,100,112,2,200, G¾ 1,5 8 40 170
22,220,24,240
3,300,4,400,418, G1 2,5 10 65 385

420,5,500,525
3,300,4,400,418, G1* 2,5 25 65 765

420,5,500,525 G1 1/4
7,700,757,760,8, G2, G2½, 11,5 30 740 1000

800,9,900,910 G3
10,1000 G4
* Innengewinde, Inside threading, Filetage intérieur
-2- GEA WTT GmbH

Anschluss an das Rohrnetz
Die effizienteste Wärmeübertragung wird realisiert, wenn Primär-
und Sekundärmedium den Wärmetauscher im Gegenstrom
durchfließen.
Ein roter bzw. blauer Punkt auf der Frontplatte kennzeichnet die
Primärseite. Die Primärseite ist der innenliegende Kanal. Somit ist
der erste und letzte Kanal eines Wärmetauschers immer auf der
Sekundärseite zu finden.
Achtung: Rohrleitungen sind so zu verlegen, dass weder
Schwingungen, Spannungen, Stöße oder Pulsationen den
Wärmetauscher beaufschlagen. Die Lebensdauer der
Wärmetauscher wird durch falsche bzw. ungenügende
Regeltechnik stark verkürzt. Hier einige Faktoren, die sich nachteilig
auf die Lebensdauer auswirken und die zu vermeiden sind:
• überdimensionierte Regelventile bzw. schlechte Qualität
• ungenügende Reglereinstellungen
• übermäßige Druckschwankungen
• falsche Platzierung der Messfühler
Achtung: Rohrsysteme in neuen und rekonstruierten Anlagen vor
Montage des Wärmetauschers spülen! Ein Filter (Maschenweite 0,8
mm für geschlossene und 0,08 mm für offene Anlagen) zur
Vorbeugung von Verschmutzungen ist an den Medieneintritten des
Wärmetauschers vorzusehen. Verschmutzungen im
Wärmetauscher können zur Korrosion und bei einigen
Anwendungen zum Einfrieren des Wärmetauschers führen!
Piping connections
In most applications the highest efficiency will be realized by
connecting the heat exchanger for counter-current flow.
The primary side of the heat exchanger is identified by a red or blue
label. The primary channels are the inner channels. The first and
last channel is always on the secondary side.
Attention: Insure that severe vibrations or pulsations cannot be
transmitted to the heat exchanger by installing vibration absorbers
in the piping and using vibration absorbing material between the
heat exchanger and the equipment. Service life of the heat
exchangers is markedly reduced by incorrect or inadequate
automatic control. Here are some factors which have a detrimental
effect on the service life. This facts should be avoided:
• Oversized regulating valves
• Excessive variations in system differential pressures
• Regulating valves of poor quality
• incorrect regulator settings
• Incorrect sensor placing
Attention: On new or renovated systems, flushing the liquid piping
to remove construction debris is recommended before connecting
the piping to the heat exchanger. A mesh size of 0,8 mm (closed
circuits) and 0,08 mm (open circuits) will retain any particle. The
strainer must be located at the inlet to the heat exchanger.
Blockage in the heat exchanger will lead to fouling or freezing of the
heat exchanger!
Raccordement au système de tuyauteries
Pour assurer un échange de chaleur optimal, les fluides primaire et
secondaire doivent circuler à contre-courant dans l‘échangeur.
Le côté primaire de l’échangeur de chaleur est identifié par une
pastille rouge ou bleu. Les canaux primaires sont les canaux
intérieurs. Le premier et dernier canal sont toujours du côté
secondaire.
Attention: Les tuyauteries sont à monter de telle façon qu’aucun
mouvement, vibration, tension ou coup de bélier ou forces divers
venant de ces tuyauteries ne puissent se répercuter sur l’échangeur
de chaleur. La longévité des échangeurs peut être réduite
considérablement par une régulation mauvaise ou insuffisante. Les
facteurs suivants agissent de manière négative sur cette longévité:
• vannes de régulation surdimensionnées
• vannes de régulation de mauvaise qualité
• mauvais réglage de ces vannes
• trop grandes variations de pression
• mauvais emplacement de la sonde de mesure.
Attention: Avant le raccordement de l’échangeur de chaleur, il faut
impérativement procéder à un rinçage de l’installation. Installer un
filtre de granulométrie 0,8 mm pour circuits fermés et de 0,08 mm
pour circuits ouverts afin de prévenir un encrassement à l’entrée de
l’échangeur. En effet, des impuretés dans le système peuvent
conduire à la corrosion et, dans certains cas d’utilisation, au gel de
l‘échangeur!
-3- GEA WTT GmbH

Achtung:
Die Wärmetauscher dürfen keine dunkleren Anlassfarben als Lötanschluss
„Strohgelb“ annehmen, da sonst Korrosionsgefahr besteht. Säubern, entfetten und polieren Sie die Oberfläche des
Keine starken Kräfte und Momente auf den Anschluss Anschlusses und des Kupferrohres. Entfernen Sie Oxide. Tragen
ausüben. Sie das Flussmittel auf. Um Oxidation zu vermeiden ist der
Wärmetauscher von innen mit Stickstoff zu schützen. Die Flamme
Warning: nicht in Richtung Wärmetauscher richten, bei max. 650 °C löten.
The heat exchangers must not develop any darker Lötmaterial: 45 - 55 % Silberlot. Benutzen Sie einen nassen Lappen
annealing colours than 'straw yellow' as otherwise (1), um den Wärmetauscher vor Überhitzung zu schützen. Halten
there is a danger of corrosion. Do not exert any high forces Sie das Rohr in einer fixierten Position beim Löten.
and torques on the connection. Achtung: Zu starke Erwärmung kann zum Schmelzen des Kupfers
und damit zur Zerstörung des Wärmetauschers führen!
Attention:
Au démarrage, la couleur des échangeurs de chaleur ne doit Schweißanschluss
en aucun cas être plus sombre qu’un jaune paille, sinon il y a WIG-Schweißung verwenden.
risque de corrosion. Benutzen Sie einen nassen Lappen, um den Wärmetauscher vor
Überhitzung zu schützen.
Um Oxidation zu vermeiden ist der Wärmetauscher von innen mit
Stickstoff zu schützen.
Beispiel einer Lötverbindung
Sample of soldering connection Gewindeanschluss
Exemple de brasage Den Wärmetauscher montieren und anschließend die
Rohrleitungen über die Gewindeanschlüsse mit dem
Wärmetauscher verbinden.
Soldering connection
Clean the soldering assembly surface at the copper tube and heat
exchanger connections. Polish the surfaces to remove oxides.
Apply the flux to the surface. In order to prevent oxidation, the heat
exchanger is to be protected from the inside with nitrogen. Do not
aim the flame in the direction of the heat exchanger, solder at a
maximum temperature of 650 °C (1200 °F). Soldering material: 45 -
55 % silver filler for brazing. Use a wet rag (1) to prevent
overheating of the heat exchanger. Hold the tube in a fixed position
during soldering.
Warning: Excessive heating can lead to fusion of the copper and
thus to the destruction of the heat exchanger!
Welding connection
Use TIG (GTAW) welding.
Use a wet rag to prevent overheating of the heat exchanger.
In order to avoid oxidation the heat exchanger has to be protected
from the inside with nitrogen.
Threaded connection
Mount the heat exchanger and then connect the pipes to the heat
exchanger by means of the threaded connections.
Raccords brasés
Nettoyez les embouts du tuyau en cuivre et les raccords de
l’échangeur de chaleur. Enlevez toutes traces d’huile ou de
poussière. Polir la surface pour enlever toute trace d’oxydation.
Utiliser de l’azote pour protéger l’intérieur de l’échangeur de toute
oxydation. Ne pas diriger la flamme de brasage vers l’échangeur de
chaleur. Chauffer la surface à braser à une température max. de
650 °C, utiliser une brasure à l‘argent à 45 - 55 %. Utiliser des
linges mouillés (1) pour protéger l’échangeur d’une surchauffe.
Tenez le tuyau dans une position fixe pendant le brasage.
Attention: Un chauffage trop intense peut provoquer la fusion du
cuivre et la destruction de l’échangeur.
Raccords soudés
Utiliser un procédé de soudage de type WIG.
Utiliser un linge mouillé pour protéger l’échangeur de toute
surchauffe.
Utiliser de l’azote pour protéger l’intérieur de l’appareil de toute
oxydation.
Raccords filetés
Monter l’échangeur de chaleur et le raccorder aux tuyauteries à
l’aide de raccords filetés.
-4- GEA WTT GmbH

Inbetriebnahme Une évacuation d’air insuffisante empêcherait un rendement
Vor Inbetriebnahme ist zu kontrollieren, dass die auf dem maximum des échangeurs de chaleur, étant donné que la surface
Typenschild befindlichen Betriebsdaten nicht überschritten werden. d‘échange ne serait pas disponible dans sa totalité. De plus, un
Überprüfen Sie die Schraubverbindungen auf Anzug. reste d’air augmente le risque de corrosion. Démarrer
Die den Wärmetauscher speisenden Pumpen müssen mit simultanément et lentement les deux côtés primaire et secondaire.
Absperrventilen ausgerüstet sein. Pumpen oder Anlagen, die Si cela n’est pas possible démarrer le côté chaud en premier.
höhere Betriebsdrücke als für den Apparat zulässig erzeugen, sind Lorsque l’installation reste longtemps à l‘arrêt, l’échangeur de
mit Sicherheitsventilen auszurüsten. Die Pumpen dürfen keine Luft chaleur est à vidanger complètement et à nettoyer, et ceci tout
ansaugen, damit es zu keinen Betriebsstörungen durch particulièrement en cas de risque de gel, d’utilisation de produits
Wasserschläge kommt. Um Druckschläge zu vermeiden, sind die agressifs ou pouvant provoquer un encrassement biologique.
Pumpen gegen geschlossene Ventile anzufahren. Die Ventile im
Vor- und Rücklauf sind möglichst gleichzeitig langsam zu öffnen bis
die Betriebstemperatur erreicht ist. Druckstöße sind zu vermeiden.
Während des Füllens ist der Apparat über die in der Rohrleitung
befindlichen Entlüftungsventile zu entlüften. Unzulänglich entlüftete
Wärmetauscher erbringen keine volle Leistung, da nicht die volle
Heizfläche zur Verfügung steht. Verbleibende Luft erhöht die
Korrosionsgefahr. Das Abfahren hat für beide Seiten (Primär- und
Sekundärseite) langsam und gleichzeitig zu erfolgen. Ist dies nicht
möglich, ist die warme Seite zuerst abzufahren. Bei längerem
Stillstand der Anlage ist der Wärmetauscher vollständig zu
entleeren und zu reinigen. Dies gilt insbesondere bei Frostgefahr,
aggressiven Medien und bei Medien, die zu biologischem Fouling
neigen.
Start of operation
Before putting the device into operation it has to be checked to
ensure that the operation data shown on the nameplate are not
exceeded.
Check the tightness of the screw connections.
The pumps feeding the heat exchanger must be equipped with
shut-off valves. Pumps which generate higher pressures than
stated for the device must be fitted with safety valves. The pumps
must not aspirate any air so that no disruptions of operation due to
water hammer occur. In order to avoid pressure surges, the pumps
are to be started up against closed valves. The valves in the supply
and return lines are to be opened slowly and, as far as possible,
simultaneously, until the service temperature is reached. Pressure
surges are to be avoided. During filling the device is to be vented
via the vent valves located in the piping. Inadequately vented heat
exchangers do not yield their full performance as the complete
heating surface is not available. Remaining air increases the danger
of corrosion. Shutdown must be effected slowly and simultaneously
for both sides (primary and secondary sides). If this is not possible,
the hot side is to be shutdown first. For a relatively long downtime of
the plant the heat exchanger is to be completely drained and
cleaned. This applies in particular when there is a danger of frost, in
the case of aggressive fluids and fluids which have a biological
fouling tendency.
Mise en service
Avant la mise en service, vérifier que les conditions d’utilisation
prévues ne dépassent pas les indications mentionnées sur la
plaque signalétique.
En outre, contrôler que tous les raccords filetés soient bien serrés.
Les pompes doivent être équipées de vannes d’arrêt. Les pompes
produisant une perte de charges supérieure à celle donnée par
notre échangeur doivent être munies de vannes de sécurité. Pour
éviter tout dysfonctionnement, les pompes ne doivent en aucun cas
aspirer de l’air. Pour éviter de soudaines poussées de pression, les
pompes doivent être démarrées vannes fermées. Les vannes dans
les circuits départ et retour sont autant que possible à ouvrir
simultanément et lentement jusqu’à ce que la température de
fonctionnement soit atteinte. Eviter toute poussée soudaine de
pression. Durant le remplissage, l’air contenu dans l’échangeur est
à évacuer via les vis de purge montées sur les conduites.
-5- GEA WTT GmbH

Betrieb Frostschutz
Nach Inbetriebnahme ist zu prüfen, dass keine Druckpulsationen Eisbildung führt zur Zerstörung des Wärmetauschers. Bei
auf den Apparat einwirken. Ist der Wärmetauscher zwischen einem Temperaturen nahe dem Gefrierpunkt ist mit Frostschutzmitteln
Stellventil und einem Differenzdruckregler eingebaut, so ist (z.B.: Glykol) zu arbeiten.
sicherzustellen, dass bei gleichzeitigem Schließen beider Zur Installation eines Temperaturfühlers ist die Ausrüstung des
Reglereinrichtungen sich kein Unterdruck bilden kann und damit Wärmetauschers mit einem G½ Innengewindestutzen möglich.
Dampfschläge vermieden werden. Diese können dem Primär- oder Sekundäranschluss
In Fernwärmesystemen ist besonderes Augenmerk darauf zu legen, gegenüberliegend angeordnet werden.
dass die sekundärseitige Druckhaltung auf die maximale
Fernwärmevorlauftemperatur ausgelegt ist. Andernfalls kann es im Anti-freeze
Teillastbereich zu Dampfschlägen kommen. Icing results in the destruction of the heat exchanger. At
Überprüfen Sie die Funktionsfähigkeit der Regeleinrichtungen. (vgl. temperatures close to the freezing point anti-freeze fluids (e.g.
„Anschluss an das Rohrnetz“) glycol) are to be used. For the fitting of temperature sensor the
Generell ist darauf zu achten, dass keine Betriebszustände fitting of the heat exchanger with a G½ internal thread socket is
entstehen können, die im Widerspruch zu dieser Montage-, possible. These can be arranged opposite the primary or secondary
Betriebs- und Wartungsanleitung stehen. connection.
Achtung:
Dampfschläge sowie Druck- und Temperaturpulsationen Protection antigel
können zu Leckagen im Wärmetauscher führen. Une prise en glace de l‘échangeur peut conduire à sa détérioration.
Es ist auf ausreichenden Potentialausgleich zu achten, um den Lorsque la température est proche du point de solidification, utiliser
Korrosionsschutz nicht zu gefährden. un antigel (par ex. du glycol). Il est possible d’équiper l’échangeur
de chaleur d’un piquage G½ permettant l‘installation d’une sonde
Operation de température à monter face au raccordement primaire ou
After the device has been put into service it is to be checked to secondaire.
ensure that no pressure pulsations are acting on the device. If the
heat exchanger is fitted between a control valve and a differential
pressure regulator, it is to be ensured that with simultaneous
closing of both regulating devices no negative pressure can form
and thus steam hammers are avoided.
In district heating systems particular attention is to be paid to the
fact that the secondary pressure maintaining system is designed for
the maximum district heating supply temperature. Otherwise steam
hammers can occur in the part-load range.
Check the functional efficiency of the control devices (cf.
“Connection to the piping network”).
It is generally to be ensured that no operating conditions can arise
which are contradictory to these assembly, operating and
maintenance instructions.
Warning:
Steam hammers, pressure and temperature cycles can lead to
leaks in the heat exchanger.
Adequate equipotential bonding is to be ensured in order not
to endanger the corrosion-proofing.
Fonctionnement
Après la mise en service, vérifier qu’il n’y ait pas de variations de
pression pouvant s‘exercer sur l’échangeur. Lorsque l’échangeur
est monté entre une vanne de régulation et un régulateur de
pression, veiller à ce qu’il n’y ait pas de sous-pression lors de la
fermeture simultanée des deux dispositifs de réglage afin d’éviter
des coups de bélier. Dans les installations de chauffage urbain,
veiller tout spécialement à ce que la pression dans le circuit
secondaire soit adaptée à la température maximale côté départ du
chauffage urbain. Dans le cas contraire, des poussées soudaines
de pression pourraient se produire. Vérifier le bon fonctionnement
des dispositifs de régulation. (Voir aussi „Raccordement au
système de tuyauteries“).
En règle générale, veiller à ce qu’il ne se produise pas de
conditions d’utilisation contraires à nos instructions de montage, de
service et d’entretien.
Attention: Toutes poussées ou variations soudaines de
pression ou de température peuvent endommager l’appareil et
provoquer des fuites dans l’échangeur de chaleur.
Veiller à un équilibre potentiel électrique suffisant pour ne pas
endommager la protection anticorrosive.
-6- GEA WTT GmbH

Verschmutzung / Fouling Reinigung
Es ist darauf zu achten, dass die DIN Richtlinien für Trink- und Sollten aufgrund der Wasserqualität (z.B. hohe Härtegrade oder
Heizungswasser, Vd-TÜV Richtlinien, Richtlinien des AGFW sowie starke Verschmutzung) eine Belagbildung zu erwarten sein, ist in
die GEA WTT Richtlinien für Wasserinhaltsstoffe eingehalten regelmäßigen Abständen eine Reinigung vorzunehmen. Es besteht
werden (siehe Folgeseite). die Möglichkeit der Reinigung durch Spülen. Den Wärmetauscher
Viele unterschiedliche Faktoren können Fouling und entgegen der normalen Strömungsrichtung mit geeigneter
Verschmutzung beeinflussen. Diese sind z.B.: Temperatur, Reinigungslösung spülen. Werden Chemikalien zur Reinigung
Strömungsgeschwindigkeit, Turbulenz, Verteilung und verwendet, ist darauf zu achten, dass diese keine Unverträglichkeit
Wasserqualität. gegenüber Edelstahl, Kupfer oder Nickel aufweisen.
Die Medien sind mit größtmöglichen Massenströmen zu fahren. Bei Nichtbeachtung kann zur Zerstörung des Wärmetauschers führen!
zu geringen Massenströmen (Teillast) kann die Turbulenz im
Wärmetauscher zurückgehen und die Verschmutzungsneigung Grundsätzlich sind die Sicherheitsvorschriften und Empfehlungen
ansteigen. der Reinigungsmittelhersteller zu beachten. Für die
Kalkablagerungen im Wärmetauscher können bei Temperaturen Reinigungsflüssigkeit nur chloridfreies bzw. chloridarmes Wasser
größer 50°C (122°F) in Abhängigkeit zur Wasserqualität auftreten. geringer Härte verwenden.
Turbulente Strömung und niedrigere Temperaturen reduzieren das
Risiko des Verkalkens. Wählen Sie das Reinigungsmittel nach Art der zu entfernenden
Beim Abfahren der Anlage ist darauf zu achten, dass zuerst die Verschmutzung sowie nach Beständigkeit der
Primärseite und dann die Sekundärseite geschlossen wird. Beim Wärmetauscherplatten. Vom Reinigungsmittelhersteller sollte auf
Anfahren wird erst die Sekundärseite und dann die Primärseite jedem Fall die Bestätigung vorliegen, dass das Reinigungsmittel
geöffnet. Dadurch wird eine Überhitzung des Wärmetauschers den zu reinigenden Plattenwärmetauscher nicht angreift.
vermieden. Reinigen Sie den Wärmetauscher entsprechend der
Arbeitsanweisung des Reinigungsmittelherstellers. Spülen Sie den
Achtung: gereinigten Wärmetauscher vor dem Wiedereinbau stets
Schlechte Wasserqualität führt zu erhöhter ausreichend mit klarem Wasser.
Korrosionsanfälligkeit!
Cleaning
Fouling Should formation of deposits due to the water quality (e.g. high
It is to be ensured that the DIN Guidelines for Drinking and Heating degrees of hardness or severe fouling) be expected, cleaning is to
Water, Vd-TÜV guidelines, guidelines of the AGFW and the GEA be carried out at regular intervals, for example by means of rinsing.
WTT Guidelines for Water Constituents are observed (see next Rinse the heat exchanger against the normal flow direction with a
page). suitable cleaning solution. If chemicals are used for cleaning, it has
Many different factors can influence fouling. These are, for to be taken care that these don`t show any incompatibility against
example, velocity, temperature, turbulence, distribution, water stainless steel, copper or nickel. Non observance can cause the
quality. destruction of the heat exchanger!
The fluids are to be moved at the highest possible mass flows. In
the event of excessively low mass flows (part load) the turbulence Always follow the safety instructions and recommendations of the
in the heat exchanger can decrease and the fouling tendency cleaning agent manufacturer. Only use chloride-free or low-chloride
increase. water with a low hardness value for the cleaning liquid.
Lime deposits in the heat exchanger can be possible at
temperatures above 50°C (122°F). Turbulent flow and lower Choose a cleaning agent suitable for the type of contamination and
temperatures reduce the risk of calcification. for the properties of the heat exchanger plate materials. In any
During shutdown of the unit it is be ensured that first the primary case, a confirmation by the manufacturer of the cleaning agent
side and then the secondary side is closed. During start-up first the should be available, stating that the agent does not affect the plate
secondary side and then the primary side is opened. In that way materials used in the heat exchanger. Clean the heat exchanger
overheating of the heat exchanger is avoided. plates according to the work instructions of the cleaning product
manufacturer.
Warning: Before reassembling the cleaned heat exchanger, always rinse
Poor water quality leads to a higher susceptibility to corrosion! them with sufficient clean water.
Encrassement Nettoyage
Les instructions DIN concernant l’eau potable et l’eau chaude Si, en raison de la qualité de l’eau (dureté extrême ou forte pollution
sanitaire, les instructions Vd-TÜV et AGFW ainsi que nos par exemple) on peut s’attendre à des risques d’entartrage, il y a
instructions sur la composition de l’eau sont à respecter (Voir pages lieu de procéder à des nettoyages réguliers, à des rinçages par
suivantes). Divers facteurs sont en mesure d’influencer exemple.
l’encrassement, par ex. la vitesse, la température, la turbulence, la
répartition du fluide, la qualité de l‘eau. Le produit de nettoyage approprié circulera dans le sens opposé au
Si le débit devait être trop faible (charge partielle) la turbulence fluide. Pour certains encrassements et dépôts tenaces à la surface
dans l’échangeur serait également faible et le risque des plaques que cette méthode de nettoyage ne permet pas
d’encrassement augmenterait. d’éliminer, il est possible d’utiliser des produits chimiques. Veiller à
Des températures supérieures à 50° C (122°F) peuvent provoquer ce que ces produits soient compatibles avec l’inox, le cuivre ou le
des dépôts de calcaire sur les surfaces internes de l‘échangeur. nickel. Dans le cas contraire, il peut s’ensuivre une détérioration de
Une augmentation de la turbulence, du débit et des températures l’échangeur!
moins élevées réduisent les risques d’entartrage.
Lors de l’arrêt de l’installation, fermer d’abord le côté primaire et Respectez toujours les consignes de sécurité et les
ensuite le côté secondaire. Pour la remise en route, ouvrir en recommandations d’utilisation du produit de nettoyage du fabricant.
premier le côté secondaire et ensuite le côté primaire. Ceci permet Diluez le produit de nettoyage dans une eau ne contenant pas ou
d’éviter une surchauffe de l’échangeur. peu d’ions chlore et de très faible dureté.
Attention:
Une eau de mauvaise qualité accroit les risques de corrosion!
-7- GEA WTT GmbH

Korrosionsbeständigkeit von gelöteten Plattenwärmetauschern gegenüber Wasserinhaltsstoffen
Der gelötete Plattenwärmetauscher besteht aus geprägten Edelstahlplatten 1.4404/1.4401 bzw. SA240 316L/SA240 316. Es ist somit das
Korrosionsverhalten von Edelstahl und dem Lotmittel Kupfer oder Nickel zu berücksichtigen.
Corrosion resistance of soldered plate heat exchangers compared to water constituents

The brazed plate heat exchangers consist of embossed plates of stainless steel 1.4404/1.4401 or SA240 316L/SA240 316. Therefore the
corrosion resistance of the stainless steel and of the brazing material, copper or nickel, must be taken into consideration.
Résistance à la corrosion des échangeurs de chaleur à plaques brasées pour les composants contenus dans l‘eau
Les échangeurs de chaleur à plaques brasées sont constitués d’un empilage de plaques corruguées en acier inox 1.4404/1.4401 ou
SA240 316L/SA240 316. Il faut donc tenir compte de la résistance à la corrosion de l’acier inox et du matériau de brasure, cuivre ou nickel.
Folgende Werte für Wasserinhaltsstoffe und für Kennwerte sollten eingehalten werden (1.4404/1.4401 - SA240 316L/SA240 316):
The following values for water constituents and parameters are to be observed (1.4404/1.4401 - SA240 316L/SA240 316):
En ce qui concerne les éléments contenus dans l’eau ne pas dépasser les valeurs suivantes (1.4404/1.4401 - SA240 316L/SA240 316):
Wasserinhaltsstoff + Kennwerte Einheit Plattenwärmetauscher, kupfergelötet Plattenwärmetauscher, nickelgelötet

Water constituent + parameters Unit Heat Exchanger, copper brazed Heat Exchanger, nickel brazed
Composants contenus dans l’eau Unité Echangeurs avec brasure au cuivre Echangeurs avec brasure au nickel
pH-Wert
pH-value 7-9 6 - 10
pH (unter Beachtung SI Index)
Sättigungs-Index SI (delta pH-Wert) Keine Festlegung
Saturation-Index SI (delta pH-value) -0,2 < 0 < +0,2 No specification
Indice de saturation SI (valeur delta pH) Pas de recommandation
Gesamthärte
Total hardness °dH 6…15 6…15
Dureté totale
Leitfähigkeit Keine Festlegung
Conductivity µS/cm 10...500 No specification
Conductivité Pas de recommandation
Abfilterbare Stoffe
Filtered substances mg/l <30 <30
Substances filtrées
Chloride Siehe Diagramm Seite 9, oberhalb 100°C keine Chloride zulässig
Chlorides mg/l See diagram page 9, above 100°C no chlorides permitted
Chlorures Voir diagramme page 9, au-dessus de 100°C pas de chlorures admissibles
Freies Chlor
Free Chlorine mg/l <0,5 <0,5
Chlore libre
Schwefelwasserstoff (H2S) Keine Festlegung
Hydrogen sulphide mg/l <0,05 No specification
Sulfure d’hydrogène Pas de recommandation
Ammoniak (NH3/NH4+ ) Keine Festlegung
Ammonia mg/l <2 No specification
Ammoniaque Pas de recommandation
Sulfat
Sulphates mg/l <100 <300
Sulfates
Hydrogenkarbonat Keine Festlegung
Hydrogen carbonate mg/l <300 No specification
Hydrogénocarbonate Pas de recommandation
Hydrogenkarbonat / Sulfat Keine Festlegung
Hydrogen carbonate / Sulphates mg/l >1,0 No specification
Hydrogénocarbonate/ Sulfates Pas de recommandation
Sulfid
Sulphide mg/l <1 <5
Sulfures
Nitrat Keine Festlegung
Nitrate mg/l <100 No specification
Nitrates Pas de recommandation
Nitrit Keine Festlegung
Nitrite mg/l <0,1 No specification
Nitrites Pas de recommandation
Eisen, gelöst Keine Festlegung
Iron mg/l <0,2 No specification
Fer Pas de recommandation
Mangan Keine Festlegung
Manganese mg/l <0,1 No specification
Manganèse Pas de recommandation
Freie aggressive Kohlensäure Keine Festlegung
Free aggressive carbonic acid mg/l <20 No specification
Acide carbonique libre Pas de recommandation
-8- GEA WTT GmbH

Die genannten Werte sind Richtwerte, die unter bestimmten Betriebsbedingungen abweichen können.
Sollten Sie Fragen haben, rufen Sie uns bitte an unter Tel. +49 3447 55 39 0.
The values stated are guide values which show variations under certain operating conditions.
Should you have any questions please call us on Phone +49 3447 55 39 0.
Les valeurs données sont des valeurs pilotes susceptibles de changer sous certaines conditions de fonctionnement. N’hésitez pas à
nous contacter si vous avez des questions Tel. +49 3447 55 39 0.
10000
Cloridgehalt, Chloride content, Chlorue
Kein Einsatz
Not permissible
1000
admissible [mg/kg]
Pas d‘utilisation
100
Einsatz ohne Probleme

No problem for application
10 Sans problémes
1
0 25 50 75 100
T e m p e ra tu r , T e m p e r a tu r e , T e m p é r a tu re [°C ]
Zulässiger Chloridgehalt in Abhängigkeit der Temperatur (1.4404/1.4401 - SA240 316L/SA240 316)

Permitted chloride content into dependence of the temperature (1.4404/1.4401 - SA240 316L/SA240 316)
Résistance à la corrosion en fonction de la température (1.4404/1.4401 - SA240 316L/SA240 316)
-9- GEA WTT GmbH

Volumenangaben GEA WTT gelötete Plattenwärmetauscher
Volume of GEA WTT brazed plate heat exchangers
Volume des échangeurs de chaleur GEA WTT à plaques brasées
BPHE BPHE
GBE…, GBS…, GBH…, * Volumen/Kanal (Liter) GBE…, GBS…, GBH…, * Volumen/Kanal (Liter)
WP…, WH…, NP… * Volume / Channel (Litre) WP…, WH…, NP… * Volume / Channel (Litre)
* Volume / Canal (en Litres) * Volume / Canal (en Litres)
100; 1 0,025 525 0,125
112 0,024 700; 7 0,230
200; 2 0,030 757 0,310
220; 22 0,046 760 0,410
240; 24 0,070 800; 8 0,221
300; 3 0,030 900; 9 0,399
400; 4; DW4 0,065 910 0,480
418 0,055 1000H; 10 0,600
420 0,076 1000L;10L 0,466
Primär/primary/primaire
500; 5; DW5 0,110 1000L;10L 0,733

Sekundär/secondary/secondaire
VP Volumen Primär:
Volume primary / Volume Côté primaire
Vs Volumen Sekundär
Volume secondary / Volume Côté secondaire
Plattenanzahl, number of plates, nombre de plaques
Beispiel, example, exemple:
BPHE: GBS100M-30
: 30
: 0,025
P...Primärseite, Primary Side, Côté primaire:
S...Sekundärseite, Secondary side, Côté secondaire:
- 10 - GEA WTT GmbH

PUR Hartschaum Isolierungen
PUR Hartschaumisolierungen bestehen aus zwei Halbschalen, die mittels zweier
Halteklammern verbunden werden. Die Montage der Isolierung erfolgt nach dem
Anschluss des Wärmetauschers an das Rohrnetz. Die Dauerwärmebeständigkeit
der Isolierung beträgt 130°C.
PU hardened polyurethane foam insulation

PU hardened polyurethane foam insulations consist of two half shells which are
bound together by two retaining clips. Fitting of the insulation is carried out after the
connection of the heat exchanger to the piping network. The durability of the heat
resistance properties is ensured up to 130°C.
Isolations en mousse de polyuréthane dure

Les isolations en mousse de polyuréthane dure sont constituées de deux coquilles
maintenues par deux agrafes. Le montage se fait après le raccordement de
l’échangeur au système de tuyauteries. Cette isolation convient pour des
applications dont la température maximale est de 130°C.
Diffusionsdichte Isolierungen
Diffusionsdichte Isolierungen bestehen aus 10/20 mm starkem geschlossenzelligen
Kunstkautschuk auf NBR Basis. Die Dauerwärmebeständigkeit der Isolierung
beträgt 105°C. Alle Teile sind passend für den jeweiligen Wärmetauscher
zugeschnitten und mit einer Klebeschicht versehen.
Installieren Sie die Isolierung erst, nachdem alle Löt- oder Schweißarbeiten
abgeschlossen sind und der Wärmetauscher abgekühlt ist. Überprüfen Sie die
Übereinstimmung von Isolierung und Wärmetauschertyp.
Nehmen Sie den Frontdeckel (1) und entfernen Sie die Klebefolie. Kleben Sie den
Frontdeckel auf die Frontplatte des Wärmetauschers (4). Kleben Sie den Enddeckel
(2), nachdem Sie die Klebefolie entfernt haben, auf die Endplatte des
Wärmetauschers (4). Nehmen Sie den Mantel (3) und entfernen Sie die Trägerfolie
der Klebeausrüstung. Kleben Sie den Mantel unter leichtem Zug um das
Plattenpaket des Wärmetauschers (4). Entfernen Sie die Klebefolie an der
Stoßkante des Mantels und kleben Sie die zwei Enden aneinander. Entnehmen Sie
der Verpackung das Kunstkautschukband und kleben Sie dieses an den Nähten um
die Anschlüsse und am Mantelstoß auf.
Diffusion resistant sealed insulation

Diffusion resistant sealed insulation consists of 10/20 mm gauge closed-pore
synthetic rubber of a NBR base with smooth surface skin. The durability of the heat
resistance properties is ensured up to 105°C. All insulation elements can be
trimmed to the size of any heat exchanger equipment and then treaded with an
adhesive coating.
Install the insulation kit after all soldering or welding is completed and the unit is
cooled down.
Check the fit of the insulation pieces to assure proper size before installation.
Take the front with adhesive (1) and remove the backing film. Press the panel in
place firmly and smooth it down with even pressure on the heat exchanger (4).
Install the rear panel (2), by removing the backing film. Install the side panel (3) by
removing the backing film. Starting at one end, wrap around the heat exchanger
with a slight stretching motion. At the end, remove the edge film and press the two
ends firmly together. Apply the thin cover pieces over the seams located around the
connections and at the place where the side panel ends meet.
Isolations NBR
Ces isolations sont faites en caoutchouc synthétique alvéolé à base de NBR.
L‘épaisseur est de 10 ou 20 mm et la surface est lisse. Cette isolation convient pour
des applications dont la température maximale est de 105°C. Elles sont livrées en
pièces autocollantes, prédécoupées et adaptées à chaque modèle d’échangeur.
Procéder au montage après achèvement de tous les travaux de brasage et de
soudure et lorsque l’échangeur est froid. Contrôler que l’isolation convient bien au
type d’échangeur.
Prenez la face avant (1), enlevez le film de protection et collez-la sur la face avant
de l’échangeur (4). Prenez maintenant la face arrière (2), enlevez le film de
protection et collez-la contre la face arrière de l’échangeur (4). Prenez l’enveloppe
(3) et enlevez le film de protection. Enveloppez l’échangeur (4) en tirant légèrement
sur l‘enveloppe. Enlevez le film de protection au point de rencontre des 2 extrémités
et appuyez ces 2 extrémités l’une contre l’autre pour bien les coller. Veiller
également à ce que l’isolation soit bien positionnée au niveau des raccordements.
- 11 - GEA WTT GmbH

Verteilerrohre
Achtung: Nur für Verdampfer-Anwendungen!
Das Verteilerrohr besteht, wie unten abgebildet, aus einer Lanze
(2), deren Länge von der Plattenanzahl des Wärmetauschers
abhängt und einem Ring (1), dessen Umfang von dem Typ des
Wärmetauschers bestimmt wird. Beide Teile werden fest verbunden
geliefert.
Die Lanze ist mit einem Schlitz versehen. Beim Einbau ist darauf zu
achten, dass dieser Schlitz nach unten gerichtet ist (6:00 Uhr).
Durch den Schlitz gelangt das noch flüssige Kältemittel in den
Wärmetauscher und gewährleistet die gleichmäßige Verteilung des
Kältemittels in die Primärkanäle. Der Ring des Verteilerrohres wird
in den primärseitigen Anschluss des Wärmetauschers mit Silberlot
AF 319 hart verlötet. Bitte beachten Sie, dass der Einbau des
Verteilerrohres bestimmte Stutzen am Kältemittel-Eintritt des
Wärmetauschers erfordert (vgl. Tabelle).
Distribution pipes
Attention: Vaporiser applications only!
The distributor pipe consists of a lance-piece (2), whose length is
dependent on the number of plates of the heat exchanger and a
ring (1), whose circumference is determined by the type of heat
exchanger. Both parts are supplied as a screw-jointed fixture. The
lance is equipped with a slot.
The distribution slot has to be mounted in the refrigerant inlet of the
vaporizer, the distribution slot must be mounted downside (6
o`clock position). The fluid refrigerant is fed into the heat exchanger
through the slot and this ensures a uniform distribution of the
refrigerant in the primary channels.
The ring of the distributor pipe is brazed as a fixture in the primary
side connection (refrigerant inlet) of the heat exchanger. Please
note, that the installation of the distributor pipe will require the
Hart löten – Silberlot AF 319 selection of certain specific connection-pieces to the heat
AF 319 silver filler for brazing exchanger (compare table).
Brasure argent AF 319
Distributeurs
Attention: Uniquement pour les échangeurs utilisés en tant
qu’évaporateurs!
Le distributeur (voir plan ci-dessous) comporte un tube (2) dont la
longueur est fonction du nombre de plaques de l’échangeur et un
anneau (1) dont le diamètre dépend du type d’échangeur choisi.
Ces deux pièces sont livrées fixées l’une à l’autre.
Le tube comporte une fente. Lors du montage veiller à ce que cette
fente soit dirigée vers le bas (Pos. 6). C’est par cette fente que le
fluide frigorigène se trouvant encore à l’état liquide, pénètre dans
l’échangeur de chaleur, assurant une répartition régulière du produit
dans les canaux du primaire. L’anneau du distributeur sera brasé
dans le raccord côté primaire de l’échangeur.
Attention: Le montage du distributeur exige des raccords
particuliers sur l’échangeur à l’entrée du fluide frigorigène.
Ø Ring/Stutzen Benötigter Stutzen am PWÜ Ø Cu-Rohr Passend für PWÜ-Typ
Ø Ring/connection Required connection Ø copper pipe Suitable for WTT heat

exchanger type
Lettre-repère pour
Ø Joint torique/raccord l’échangeur de chaleur Ø tube en cuivre Convient pour l‘échangeur de
chaleur
18 mm
35 mm K 22 mm NP5, WP5, GB…500
28 mm
42 mm LZ 22 mm NP7, WP7, GB…700
54 mm L 22 mm WP8, GB…800, WP9,

GB…900
- 12 - GEA WTT GmbH

050101.100706.02
9 Valves, Fittings and Assembly

Ventile, Armaturen und Zubehör
9.1 Valves
Ventile
Ball Valve, 2-way
2-Wege Kugelhahn
Ball Valve
Kugelhahn
Type DKA
Type NKB
Straight Through Control Valve
Durchgangs-Stellventil
Type 440
Actuator, Electric-type
Antrieb, elektrisch
Safety Valve
Sicherheitsventil
Type 961
Solenoid Valve
Magnetventil
Type GMV 3197
Type 330
Type 331
Non Return Valve
Rückschlagventil
Type MR
Type RK 41
Gate Valve
Muffenschieber
Pressure relief valve
Druckbegrenzungsventil
Type SPVF
9.2 Other Parts
Sonstige Teile
Steam Trap
Kondensatableiter
Type FT-14
Wartungseinheit
Type C06-K10

Ball Valves
Operation and Installation Manual
END-Armaturen GmbH & Co. KG

Postfach (PLZ 32503) 100 341 · Oberbecksener Str. 78 · D-32547 Bad Oeynhausen · Telefon (05731) 7900-0 · Telefax (05731) 7900-80 · http://www.end.de
Impressum
© by END-Armaturen GmbH & Co. KG
All rights reserved. END-Armaturen GmbH & Co. KG claims copyright over this documentation.
This documentation may neither be altered, expanded , reproduced nor passed to third parties without the
written agreement of END-Armaturen GmbH & Co. KG . This restriction also applies to the corresponding
drawings.
END-Armaturen GmbH & Co. KG has the right or change parts of the valves and armatures at any time without
prior or direct notice to the client. The contents of this publication are subject to change without notice.
This publication has been written with great care. However, END-Armaturen GmbH & Co.KG cannot be held
responsible, either for any errors occuring in this publication or for their consequences.
The products are specified by the statements in this documentation; no assurance or the properties is given.

Oberbecksener Straße 78
D-32547 Bad Oeynhausen
Telefon: 05731 / 7900 - 0
Telefax: 05731 / 7900 - 80
Internet: http://www.end.de
E-Mail: post@end.de
Edition: 11/02
2 http://www.end.de 13.11.02
Contens
Contens
1 Foreword 4
2 General advice 5
2.1 Validity 5
2.2 Inward monitoring 5
2.3 Complaints 5
2.4 Guarantee 5
2.5 Symbols and their signification 6
3 Safety advice 7
3.1 Personal advice 7
3.1.1 Safety advices for mounting 7
3.1.2 Safety advice for adjustment / starting 7
3.1.3 Safety advice for maintaining / repairing 8
3.2 Device safety 9
4 Name-plate 10
5 Ball valves 11
5.1 General 11
5.2 Corresponding use 11
5.3 Operation 11
5.4 Mounting / Disassembly 11
5.4.1 Mounting with threaded connection 12
5.4.2 Mounting with welded connection 13
5.4.2.1 Disassembly of the center part of the ball valve 13
5.4.2.2 Welding of the connection ends 14
5.4.2.3 Mounting of the center part 15
5.4.3 Mounting with flanged connection 16
5.5 Maintenance 17
5.5.1 Readjusting of the gland 18
5.5.2 Exchange of the ball and the sealing 19
5.5.2.1 3-part ball valve with threaded or welded connection 19
5.5.2.2 Multiple part ball valve with flanged connection 22
13.11.02 http://www.end.de 3
Foreword
1 Foreword
Dear customer,
Dear assembler / user,
these operation and installation manuals are intended to give you the knowledge, which is
necessary for you to be able to carry out the mounting and adjustment of the ball valves rapaidly
and correctly.
Please read these instructions carefully and pay particular attention to the advice and warning
notes.
Only instructed and qualified mechanician should mount, adjust or maintain the ball valves.
If you have any questions in relation to the ball valves we shall be pleased to answer them.
The telephone number will be found on the inside cover of these operation and installation
manual.
Yours
General advice
2 General advice
2.1 Validity
These mounting and installation manual is valid for the standard version of the ball valves.
2.2 Inward monitoring
Please check
• directly after delivery the ball valves for any transport damages and defi-
ciencies.
• with reference to the accompanying delivery note the number of parts.
Do not leave any parts in the package.
2.3 Complaints
Claims for replacement or goods which relate to transport damage can only be considered valid if
the delivery company is notified without delay.
In case of returns (because of transport damage / repairs), please make a damage protocol and
send the parts back to the manufacturer, if possible in the original packaging.
In case of a return, please mention the following:

• Name and address of the consignee
• Stock-/ ordering-/ article-number
• Description of the defect
2.4 Guarantee
For our ball valves we give a guarantee period in accordance with the sales contract.
The end of the normal duration of life of the wearing parts represents no defect.
The warrenty and guarantee rules of END-Armaturen GmbH & Co. KG are applicable.
Symbols and their signification
2.5 Symbols and their signification
Paragraphs which are identified with this symbol contain very important advices; this also includes
advices for averting health risks. Observe these paragraphs without fail!
Paragraphs which are identified with this symbol contain very important advices, this also includes
how to avoid damage to property. Observe these papgraphs without fail!
This symbol indicates paragraphs which contain comments / advices or tips.
This spanner identifies the description of actions which you should carry out.
Safety advice
3 Safety advice
Depending on the technical circumstances and the time under and at which the armatures and
valves are mounted, adjusted and commissioned, you must take into account particular safety
aspects in each case!
If, for example, a pneumatic actuator works a slide in an operational chemical plant, the potential
hazards of commissioning have another dimension from that when this is only being carried out for
test purposes an a „dry“ part of the plant in the assembly room!
Since we do not know the circumstances at the time of the mounting/adjustment/commissioning,

you may find advices on hazards in the following descriptions which are not relevant to you.
Please observe (only) the advices which applies to your situation!
3.1 Personal advice
3.1.1 Safety advices for mounting
We wish to point out expressly that the mounting, adjusting and at accessories the pneumatical
and eletrical installation of the armatures and valves must be carried out by trained specialist
personnel having mechanical, pneumatical and electrical knowledge!
Secure that the machine / plant come up to the Machinery Directice after the mounting and instal-
ling of the armatures and valves.
Switch off all the devices / machines / plant affected by mounting or repair.
If appropriate, isolate the devices / machines / plant from the mains.
Check (for example in chemical plants) whether the switching off of devices / machines / plant
will cause potential danger.
If appropriate, in the event of a fault in the armature / valve (in a plant which is in operation)
inform the shift forman / safety engineer or the works manager without delay about the fault, in
order, for example, to avoid an outflow / overflow of chemicals or the discharge of gases in good
time by means of suitable measures!
Before mounting or repairing, remove the pressure from pneumatic / hydraulic devices / machi-
nes / plant.
If necessary, set up warning signs in order to prevent the inadvertent starting up of the devices /
machines / plant.
Observe the respective relevant professional safety and accident prevention regulations when
carrying out the mounting / repair work.
Check the correct functioning of the safety equipment (for example the emergency push off but-
tons/ safety valves, etc)!
3.1.2 Safety advice for adjustment / starting
As a result of the starting (pneumactic, electric or by hand) of the armatures and valves the flow
of gases, steam, liquids, etc. may be enabled or interrupted! Satisfy yourself that, as a result of
the starting or the test adjustment no potential hazards will be produced for the personnel or the
environment!
Safety advice
If necessary, set up warning signs in order to prevent the inadvertent starting up or shutting down
of the device / machine / plant.!
By ending the adjustment check the correct function and should the occasion arise the position
of the slide / valve / flap.
Check the function of the limit switches (option)!
Check, whether the slide / valve / flap will be closed totally, if the control signals the appropriate
limit stop!
Through suitable measures, prevent links being trapped by moving actuating elements!
Check the right function of all safety devices (for example emergency push off buttons / safety
valves)!
Carry out the starting and the adjustments only in accordance with the instructions discribed in
this documentation!
Adjusting switch on armatures and valves with options (e.g. actuators, solenoid valves, limit
switches) there is the risk that live parts (230 V AC~) can be touched!
Therefore the adjustments must be carried out only by the electrican or a person having adequate
training, who is aware of the potntial hazard!
3.1.3 Safety advice for maintaining / repairing
Do not carry out any maintenances / repairs if the armature / valve will be under pressure.
Before disassembling or a armature or valve some essential points should be clarified!

• Will the armature/valve to be disassembled be replaced by another immediately?
• If appropriate, does the production process of the plant needed to be stopped?
• Is it necessary to inform specific personnel about the disassmbly?
If necessary, inform the shift foreman/ safety engineer or the manager about the maintenance
or repair without delay in order, for example, to avoid an outflow/ overflow of chemicals or a
discharge of gases in good time by means of suitable measures!
Observe that some valves / armatures are able to enclose the pressured medium e.g. the ball
in the ball valve. You have to relieve the pressure in the pipes in which the armture/valve is
mounted.
Switch off pilot pressure and the power supply and relieve the pressure in the pipes.
If necessary set up warning signs in order to prevent

• the inadvertent starting up of the devices/machines/plants in which the armature/
valve is mounted
• the switching on of pilot medium supply, pilot power supply and/or the power supply
of actuators and accessories.
In case of defect in the armature/valve make contact to the supplier. The telephone number will
be found on the back cover of these mounting and installation manual.
Safety Advice
If you ascertain a damage of the armature/valve, isolate the device from the mains. Please
observe the safefy advices.
Do not mount, start or adjust the armature/valve if itself, the pipes or a mounted actuator will be
damaged.
After the maintenance or repair check the right function of the armature/valve and the tightness
of the pipe connections.
Also check the function of the accessories e.g. actuators, limit switches, etc.
3.2 Device safety
The armatures/valves
• are quality products which are produced in accordance to the recognized industrial
regulations.
• left the manufacturer`s work in a perfect safety condition.
In order to maintain this condition, as installer / user you must carry out your task in accordance
with the description in these instructions, technically correctly and with the greatest possible
precision .
We assume, as a trained specialist you are having mechanical and electrical knowledge!
Satisfy yourself that the armatures/vales will only be used within their admissible limiting value
(see the technical data) .
The armatures/valves must be used only for a purpose corresponding to their construction!
The armatures/valves must be used within the values specified in the technical data!
The operating of the armature/valve outside the nominal temperature range could destroy the
sealings and the bearings.
The operating of the armatures/valves outside the nominal pressure range could destroy the inner
parts and the body.
Never remove a cap or a other component part if the armature/valve will be under pressure.
Do not mount, start or adjust the armature/valve if itself, the pipes or a mounted actuator will be
damaged.
After the maintenance or repair check the right function of the armature/valve and the tightness
of the pipe connections.
Name-plate
4 Name-plate
In some cases the armatures/valves will be provided with a nameplate, which permitts a definite identification
of the armatures/valves and shows the most important technical data to you. The name-plate should not be
displaced or changed

+49 (0)5731 - 7901-0 www.end.de
Art. No.: AE311028
Serial: 220885
Pressure range (PS): 16 bar
Pilot pressure: - bar
Temperature range (TS): -20°C ... +180°C
Size (DN): 50 / G2"
Testing pressure (PT): 60 bar
Fluidgroup: 1
Date of manufacturing: 14.02.2002
0062
Fig. 4.1 - Name-plate
Art.No. article number of the valve / armature

Serial order- or production- number
Pressure range (PS) max. admisable working pressure of the valve / armature [bar]
Pilot pressure recommend pilot pressure for correct function of the valve / armature [bar]
(only at pneumatic actuated valves / armatures)
Size (DN) connecting size of the valve / armature
Testing pressure (PT) testing pressure of the body of the valve / armature
Fluidgroup allowed fluidgroup of the valve / armature
Date of manufacturing month and year of manufacturing of the valve / armature
Ball Valves
5 Ball valves
5.1 General
Before you are mount, adjust, start, operate or disassemble a ball valve you have to read the
Safety advices
If you have not read the safety advices until now, read this important advices now and turn back
to this point.
5.2 Corresponding use
Ball valves will be used to cut off medium flow.

It should only be used clean liquids and gases, on which the material of the ball valve will be resis-
tant. Pollution or using outside the nominal pressure range and/or the nominal temperature range
should causes damages on the armature especially on the seals.
In some cases you have to install an equalization boring into the ball, that there will be no overpres-
sure between the body and the ball by changing temperatures.
5.3 Operation
The ball valve will be open or close totally by using a handle or an pneumatic or electric actuator
(option).
During the operation of the ball valve take care that there won`t be insert any objects or limbs
into the armature. Heavy injuries or damages will be the consequence. If it is necessary you have
to install a protective device.
5.4 Mounting / Disassembly
The mechanical installation will be same at all variants of the ball valve. There will be differences
in the type of connection.
Observe the flow direction: the handle should point at the flow direction.
Remove the package and the safety devices (e.g. caps or plugs). Take care that there will be no
parts of the package or other parts in the armature.
Clean up the pipes in which the ball valve will be mounted. Pollution could affect the safety in
operation and the duration of life of the armature. If necessary you have to install a Y- strainer in
front of the ball valve.
Avoid stress in case of non align pipes.
Ball valves
5.4.1 Mounting with threaded connection
Before lay on sealing compounds, check the hardly screwing by the pipes into the valve body.
Lay on the correct sealing compounds on the pipes end. By using PTFE-ribbon or hemp sealings
observe the screw direction. Don`t use sealing compounds which are not prescribed for your emp-
loyment.
Screw the pipes into the connection ends of the valve. Don`t use the handle as a lever.
Strike up the pipes with pressure after that time the manufacturer of the sealing compounds pre-
tends to harden it.
Check the tightness of all connections.
sealing compound
harden
o.k.
flow direction
Fig. 5.1 - ball valves, mounting threaded connection (Fig.: Art. TB111025)
Ball valves
5.4.2 Mounting with welded connection
Before welding you have to disassemble the center part of the ball valve to prevent the sealings
from damages.
5.4.2.1 Disassembly of the center part of the ball valve
Clamp the valve between a vice carfully. By using guard plates you can prevent the damage of the
ends of the body.
Loosen the nuts crossvice and remove the screws out of the body.
Take the center part of the ball valve. Observe, that you didn´t drop the sealings or the ball. Put the
parts aside carefully. To attach the center parts and the connection ends at a later mounting you
can sign the parts.
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Fig. 5.2 - ball valves, mounting welded connection, disassembly of the center part (Fig.: Art. ZE311064)
Ball Valves
5.4.2.2 Welding of the connection ends
The center part of the ball valve must be substitute by a distance part as long as the center part
during the welding.
By welding the valve body with the pipes observe appropriate demands and guide lines.
The safety demands by welding are depending on the place and the position of the point of weld.
Welding the parts at a serviceable device/machine/plant the potential of danger is as higher as
welding the parts in a welding room.
If appropriate, inform the shift foreman/safety engineer or the works manager and the fire brigade
of your factory.
By welding observe your own national guide lines about safety and pevention of accidents.
Fig. 5.3 -ball valves,mouting welded connections, welding of the connection ends(Fig.: Art. ZE311064)
Ball valves
5.4.2.3 Mounting of the center part
Before mounting the center part let the connection ends cool down.
Disassemble the distance part.
Insert the center part between the connection ends. Attach the center parts to the right connection
ends.
Observe the correct seat of the sealings and that there will be no pollution in the seats of the
sealings and in the ball.
Insert the screws into the borings of the connection ends.Tighten the nuts equally and crosswise.
Observe the max. torque of the screws.
Check the function of the ball valve.
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Fig. 5.4 - ball valves, mounting welded connections, mounting of the center part of the ball valve (Fig.: Art. ZE311064)
Ball valves
5.4.3 Mounting with flanged connection
In the following discription we assume that you have mounted the flanges at the end of the pipes
and the ball valve (welded flanges) and they are cooled down.
Insert the ball valve and the flange sealings between the flanges.
Align the flange borings und put fit screws through the borings.
Put fit nuts on the screws and tighten them equally and crossvice. Observe the max. torque of the
screws.
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Fig. 5.5 - ball valves, mounting flanged connection (Fig.: Art. ZP311007)
Ball valves
5.5 Maintenance
Before you maintain or shut down the valves you have to read the
Safety advice
to this point.
On normal accounts the ball valve is maintenance free.In periodical turns the controlling of the
function and the tightness should happen:
• check the tighness of the gland

• check the tightness of the ball seats
Depending on the version of the ball valve for decreasing tightness at the stem the gland could be
readjust. See also chapter 5.5.1. „Readjusting of the gland“.
Ball valves in a multiple part design could be disassemble to exchange the seals and/or the ball.
See also chapter: 5.5.2. „Exchange of the ball and the sealings“.
In case of a defect of the valve make a contact to the supplier. The telephone number will be
found on the back or these operation and installation manual.
If you ascertain a demage of the valve switch off the device/ machine/ plant! However before
doing this, it is essential to refer to the
Safety advice.
Ball valves
5.5.1 Readjusting of the gland
For decreasing tightness at the stem the gland could be readjust.
By keeping the nominal pressure you have to tighten up the screw of the gland until the tightness
of the the gland will be restored
After the readjusting the ball of the valve must be able to move slightly.
At ball valves with spring forced sealings or o-ring sealings at the stem the readjustment isn`t
necessary.
o.k. tightness
Fig. 5.6 - ball valves, readjusting of the gland (Fig.: Art. ZE311064)
Ball valves
5.5.2 Exchange of the ball and the sealing
For decreasing tightness the ball and/or the sealings of the ball valve could be exchange. The
availability of the spare parts kit you can see in the data sheet of your ball valve.
Corresponding to the wear of the parts exchange the sealings and the ball. By the replacement of
the ball you should also exchange the sealing.
In the following description we assume, that your ball valve will be actuated by hand. If your ball
valve will be actuated be a pneumatic or electric actuator, please also observe the opration and
installation manual of the actuator.
Cut off the media flow and relieve the media pressure.
Keep ready some fit tanks to catch up leaking liquids.
If it`s necessary remove the additional limt switches and gear boxes.
5.5.2.1 3-part ball valve with threaded or welded connection
At 3-part ball valve it will do when you remove the center part of the ball valve. Loosen the nuts
crosswise and remove the screws out of the body.
Take the center part of the ball valve. Observe, that you didn´t drop the sealings or the ball. Put the
parts aside carefully.
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Fig. 5.7 - ball valves, replacement of the sealing kit: removement of th center part (Fig.: Art. ZE311064)
Ball valves
Observe that ball valves could enclose medium inside the ball.
Take the parts aside carefully. Place a mark on the body and the connection ends that you will be
able to join the correct parts by a subsequent mounting.
Remove the ball seals and the ball out of the body.
Perhaps you have to turn the handle to remove the ball out of the body. Do not insert any limbs into
the ball valve. Heavy injuries will be the consequences.
Loosen the nut of the handle and take the handle and all discs und washers aside.
Depending on the version of the ball valve loosen the nut on the stem or loosen the gland nut
Remove the stem and all other sealings, washers and discs out of the body.
Clean all parts and check them for damages.
Throw away the old pieces by observing the appropriate demands and guide lines.
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Fig. 5.8 - ball valves, replacement of the sealing kit: removement of the inner parts (Fig.: Art. ZE311064)
Ball valves
Make the stem with the new sealings and discs complete.
Insert the stem from the inside into the body.
Depending on the version of the ball valve mount the other sealings, discs and spring washers at
the stem, and screw the nut or the gland nut onto the stem.
Insert the ball into the body. The dihedral of the stem must engage in the grove of the ball. If need
be you have to turn the stem.
Put the handle onto the stem. Observe the correct function of the limit switches and take care that
the handle and the boring of the ball will align.
Fix the nut of the handle onto the stem and tighten it.
Put the ball sealings and the ball into their seats at the center part of the ball valve. Observe, that
you didn´t drop the sealings or the ball.
Before mounting the center part clean the connection ends at the end of the pipes.
Move the center part of the body between the connection ends. If need be arange the center parts
to the correct connection ends.
Insert the screws into the borings of the connection ends.Tighten the nuts equally and crosswise.
Observe the max. torque of the screws.
For mounting read the advices at chapter
5.4.2.3. „Mounting of the center part“.
Check the tightness of all the connections.
If need be adjust the gland of the stem. Please read the advices at chapter
5.5.1. „Readjusting of the gland“.
Ball valves
5.5.2.2 Multiple part ball valve with flanged connection
Remove the ball valve out of the pipes. Loosen the flange screws and pull the screws out of the
flange.
Take the ball valve from the pipes.
Dismantle the ball balve. Depending on the version of the ball valve:
• you have to screw out the screw of the body, or
• you have to screw the screw joint out of the body.
Observe, that you didn´t drop the sealings or the ball.
Observe that ball valves could enclose medium inside the ball.
Put the parts aside carefully. Place marks on the parts that you will be able to join the correct parts
by a subsequent mounting of the ball valve.
Remove the ball sealing and the ball out of the body.
Fig. 5.9 - Ball valves, replacement of the sealing kit: removement of the ball valve (Fig.: Art. ZP311007)
Ball valves
Perhaps you have to turn the handle to remove the ball out of the body. Do not insert any limbs into
the ball valve. Heavy injuries will be the consequences..
Remove the second ball sealing.
Loosen the nut of the handle and take the handle and all discs und washers aside.
Depending on the version of the ball valve loosen the nut on the stem or loosen the gland nut
Remove the stem and all other sealings, washers and discs out of the body.
Clean all parts and check them for damages.
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Fig. 5.10 - ball valves, replacement of the sealing kit: removement of the inner parts (Fig.: Art. ZP311007)
Ball valves
Make the stem with the new sealings and discs complete.
Insert the stem from the inside into the body.
Depending on the version of the ball valve mount the other sealings, discs and spring washers at
the stem, and screw the nut or the gland nut onto the stem.
Place the first ball seal into the seat in the body.
Insert the ball into the body. The dihedral of the stem must engage in the grove of the ball. If need
be you have to turn the stem.
Place the second ball seal into the seat in the body.
Assemble the ball valve. Depending on the version of the ball valve:
• you have to join the parts of the body together and to screw them up with the fit
screws; or
• you have to screw up the screw joint with the body.
If need be attach the different parts of the boby.
Put the handle onto the stem. Observe the correct function of the limit switches and take care that
the handle and the boring of the ball will align.
Fix the nut of the handle onto the stem and tighten it.
Before mounting the center part clean the connection ends at the end of the pipes.
Insert the ball valve with new flange sealings between the flanges.
Align the flange borings und put fit screws through the borings.
Put fit nuts on the screws and tighten them equally and crossvice. Observe the max. torque of the
screws.
For mounting read the advices at chapter
5.4.3 „Mounting with flanged connection“.
Check the tightness of all the connections.
If need be adjust the gland of the stem. Please read the advices at chapter
5.5.1. „Readjusting of the gland“.
(1) Declaration in conformity
(2) as defined by Pressure-Equipment-Directive 97/23/EG
(3) Herewith we declare that the supplied articles:
AA, AB, AC, AD, AG, AK, AR, BE, BF, BG, BH, BK, CA, CB, CD, CK, CU, CV, CW, DK, EA, EA, EB, EK, FG,
HK, IC, IG, IK, IL, KA, KU, MA, MB, MD, MR, NG, NK, PB, PD, RG, RK, RM, SD, SK, SV, TA, TB, TC, TD,
TE, TF, TH, TR, UV, VA, VC, VD, VH, VK, VL, VM, VN, VO, VS, VT, VU, WG, ZA, ZD, ZE, ZF, ZG, ZK, ZP,
ZR, SONV, and all variations of these articles
(4) of the company END-Armaturen GmbH & Co. KG

Germany
(5) are in conformity with the regulations of the directive 97/23/EG.
(6) Applied conformity assessment PED: Modul H.
(7) Notified body for conformity assessment PED an Quality-Management-System:
Bureau Veritas S.A.

Paris / Frankreich
Kennzeichen 0062
(8) Applied harmonized standards, in particular:
DIN 3840:1982 Armaturengehäuse

Festigkeitsberechnung gegen Innendruck
(9) On behalf Bad Oeynhausen, 20. Juli 2004
Friedhelm König Michael End

Technical Manager Quality Manager

Postfach (PLZ 32503) 100 341 · Oberbecksener Str. 78 · D-32547 Bad Oeynhausen (Germany) · Telefon +49 - 5731 - 7900-0 · Telefax +49 - 5731 - 7900-80 · http://www.end.de
Notes
Notes
PRODUCTS
We are developing and producing sophisticated industrial fittings proving every day in the field.
This is supported be our fullfilling the requirements of Quality Standard DIN EN ISO 9001.
Satisfied partners and success are proving that the investment for quality and protection of the
environments is worthwhile.
END-ARMATUREN GMBH & CO. KG END-AUTOMATION GMBH & CO. KG

OBERBECKSENER STR.78 OBERBECKSENER STR.78
D-32547 BAD OEYNHAUSEN D-32547 BAD OEYNHAUSEN
POSTFACH (PLZ 32503) 100 341 POSTFACH (PLZ 32503) 100 342
TELEFON +49 (0) 5731 / 7900-0 TELEFON +49 (0) 5731 / 7901-0
TELEFAX +49 (0) 5731 / 7900-80 TELEFAX +49 (0) 5731 / 7901-98
INTERNET http://www.end.de INTERNET http://www.end.de
E-MAIL post@end.de E-MAIL post@end.de
Dreiteilig handbetriebene Kugelhähne
Three pieces ball valve with hand lever DEUTSCH
ENGLISCH
Betriebs- und Wartungsanleitung

Installation and Maintenance
Bitte lesen Sie vor Installation Ihrer Armatur diese Betriebs- und Wartungsanleitung sorgfältig
durch.
Die Installation und Wartung darf nur durch qualifiziertes Personal durchgeführt werden.
Bitte beachten Sie die in dieser Anleitung aufgeführten Sicherheitshinweise!
Before installing and maintaining your valve, read this manual carefully.
Installation and maintanance is allowed for skilled employees only.
Please pay attention to the safety advices!
Steuert. | Spart. | Schafft Mehrwert.

BW-3Tlg-KH-H-Gew-05-01
©2005 - MIT Armaturen GmbH, Vlotho
Alle Rechte an Texten und Bildern, auch die der Übersetzung, sind vorbehalten.
Dieses Handbuch darf nicht, auch nicht in Auszügen, in irgendeiner Form (Druck, Fotokopie, Mikrofilm oder
weitere Verfahren) ohne schriftliche Zustimmung reproduziert oder unter Verwendung elektronischer Systeme
verarbeitet, vervielfältigt oder verbreitet werden.
The property rights of all texts and pictures are subject to MIT Armaturen GmbH. It is not allowed to change or
duplicate even parts of it without written permission. We do not assume responsibility for correctness and
integrity. Colours of original products can differ from images.
Änderungen sind vorbehalten.

Errors excepted regarding print and technical changes.
Auflage: April 2005, Revision 1

Edition: April 2005 Revision 1
Anfragen richten Sie bitte schriftlich an:

MIT Armaturen GmbH
Industriestr. 9
32602 Vlotho
-2-
BW-3Tlg-KH-oW-AE-05-01
Inhaltsverzeichnis
Seite / page
Zu dieser Anleitung -4-

This manual
Abkürzungen und Symbole - 4-
Shortcuts and symbols
Leistungsbeschreibung -5-
Specification of service
Bestimmungsgemäße Verwendung -5-
Intended usage
Lagerung, Transport, Entsorgung -5-
Storage, transport, disposal
Allgemeine Einsatzbedingungen -5-
Terms of general application
Gerätebeschreibung -6-
Device description
Wartung -6-
Maintenance
Inbetriebnahme und Wartung -7-

Acticity description
Installation und Inbetriebnahme -7-
Installation
-3-
DEUTSCH BW-3Tlg-KH-H-Gew-05-01
Zu dieser Anleitung
Ziel der Anleitung
Die vorliegenden Informationen ermöglichen es Ihnen, die Armatur fachgerecht zu

installieren und zu warten.
Die Anleitung richtet sich an technisch qualifiziertes Personal. Es wird vorausgesetzt, dass
bestimmtes Fachvokabular verstanden wird und dass technische Zeichnungen gelesen
werden können.
Sollte dies nicht der Fall sein, informieren Sie bitte Ihren zuständigen Kundenbetreuer
bei MIT.
Aktuelle Dokumentation im Internet
Wir bitten Sie, sich regelmäßig über aktualisierte Versionen dieser Anleitung zu informieren.
Diese Anleitung unterliegt nicht der Revisionierung und stellt lediglich den zum Zeitpunkt
des Drucks aktuellen Informationsstand der MIT Armaturen GmbH dar. Aktuelle
Informationen zu Ihrem Produkt können Sie jederzeit unter www.systemarmaturen.de
abrufen.
Gültigkeit der Anleitung
MIT Armaturen behält sich Änderungen an der Armatur sowie Erweiterungen und
Änderungen der vorliegenden Anleitung, die dem technischen Fortschritt dienen, vor.
Abkürzungen und Symbole
Achtung! Bitte Achtung! Heiße

lesen! Oberfläche!
Werkzeug Vorsicht!
notwendig Spannung
Zu Ihrer Dokumente
Information beachten
Verletzungs- Hinweis auf

gefahr! Anleitung
Betriebsstoff
notwendig
-4-
BW-3Tlg-KH-oW-AE-05-01 DEUTSCH
Leistungsbeschreibung
Bestimmungsgemäße Verwendung
Hanbetätigte Kugelhähne der Baureihen DKA04 und DKA07 der MIT Armaturen GmbH
sind zum Einsatz im industriellen Bereich geeignet. Die Armaturen ermöglichen das
Absperren gasförmig- und flüssiger Medien. Die Gehäuse- und Dichtmaterialien müssen für
das eingesetzte Medium und den angegebenen Temperaturbereich geeignet sein.
Verletzungsgefahr
Hineinführen von Körperteilen und Gegenständen in den Kugelhahn kann zu

schweren Verletzungen führen und sollte unbedingt vermieden werden!
Lagerung, Transport, Entsorgung
MIT-Produkte sind i.d.R. durch Umverpackungen vor äußeren Einflüssen wie Feuchtigkeit oder
Schmutz geschützt. Wir empfehlen, diese Umverpackung erst kurz vor Montagebeginn zu
entfernen, um die Geräte vor Verunreinigungen zu schützen.
Bei Einlagerung ist darauf zu achten, dass die Geräte trocken und schmutzfrei untergebracht
werden.
Lange Lagerzeiten können eine Erhöhung des Losbrechmomentes zu Folge haben. Erst nach
Betätigung des Kugelhahns wird das Nenndrehmoment wieder erreicht.
Auf die Handhabung beim Transport können wir jedoch nur mit Ihrer Hilfe Einfluss nehmen – bitte
informieren Sie uns unverzüglich wenn die Ware bereits mit beschädigter Verpackung bei Ihnen
eintrifft! Die Kontrolle der Produkte muss unmittelbar nach Wareneingang erfolgen und sollte eine
Prüfung der technischen Parameter und eine Sichtprüfung beinhalten. Verdeckte Mängel sind
unverzüglich nach Entdeckung zu rügen, andernfalls gilt die Ware als genehmigt.
Warenmängel oder Abweichungen der Menge müssen spätestens

7 Tage nach Erhalt der Ware schriftlich angezeigt werden, andernfalls
erlischt der Gewährleistungsanspruch!
Allgemeine Einsatzbedingungen
Rohrleitungen sollten vor Einbau, spätestens jedoch vor Inbetriebnahme durchgespült werden.
Automatisierte Armaturen bedürfen einer besonderen Beachtung bei der Inbetriebnahme! Diese
Geräte können im Werk nur unter Werkstattbedingungen getestet und eingestellt werden.
Sicherheitsstellungen sollten gezielt simuliert und getestet werden. Die Endlagen
(offen/geschlossen) müssen überprüft und ggf. nachjustiert werden! Zusätzliche Wegschalter oder
andere elektrische Geräte zur Stellungsrückmeldung ebenfalls auf richtige Justierung überprüfen!
-5-
DEUTSCH BW-3Tlg-KH-H-Gew-05-01
Gerätebeschreibung
1. Mutter
2. Handhebel
3. Stopfbuchsmutter
4. Spindel (wird von unten eingeführt)
5. Stopfbuchse
6. Sitzdichtung
7. Gehäusemutter
8. Federring
9. Gehäuseschraube
10. Gehäuseende
11. Gehäusedichtung
12. Kugel
13. Körper
14. Anlaufring
15. Stopfbuchspackung (3 Tlg.)
16. Unterlegscheibe
Wartung
Bevor der Kugelhahn gewartet werden kann, müssen alle Zu- und Ableitungen drucklos
geschaltet werden.
Bei wieder Zusammenbau des Kugelhahns darauf achten, dass die Gehäuseschrauben
gleichmäßig und über Kreuz angezogen werden!
Folgende Wartungsgründe sind mögich:
Fehler Mögl. Ursache Abhilfe

Stopfbuchsmutter Stopfbuchsmutter nach
Undichtigkeit
gelöst ziehen
Kugel durch
Bitte setzen Sie sich mit
Medium/Schmutz in
Undichtigkeit ihrem Servicepartner in
den Leitungen
Verbindung
verschlissen
Kugelhahn Verschmutzung der Reinigen der Kugel /
Schwergängig Kugel des Kugelhahns
-6-
BW-3Tlg-KH-oW-AE-05-01 DEUTSCH
Tätigkeitsbeschreibung
Installation und Inbetriebnahme eines Kugelhahns mit Gewindeanschluss
Der Einbau darf nur in drucklosem Zustand erfolgen.

Missbrauchen Sie bei der Montage den Handhebel nicht als Hebel!
Zum Anschluss des Kugelhahns an Ihr Rohrsystem benötigen Sie eine Schlüsselweite
von X mm.
Den Kugelhahn vorsichtig in einen Schraubstock spannen (die Verwendung

von Schutzbacken verhindert Beschädigungen der Gehäuseenden).
Verschraubungen kreuzweise und gleichmäßig lösen und Schrauben
herausnehmen.
Bitte achten Sie darauf, dass das verwendete Dichtmittel für das Durchlfuss-Medium
geeignet ist!
Kugelhahnmittelteil vorsichtig herausnehmen. Î

Dabei darauf achten, dass die Dichtungen und die Kugel nicht
herausfallen.
Geeignetes Dichtmaterial an die Rohrleitungsenden anbringen, bei PTFE-Band

oder Hanfdichtungen die Einschraubrichtung beachten. Nur dem Einsatzzweck
entsprechende Dichtmaterialien verwenden
Gehäuseenden fest anschrauben und Kugelhahn montieren.

Gehäuseschrauben gleichmäßig und über Kreuz anziehen.
-7-
ENGLISH BW-3Tlg-KH-H-Gw-05-01
This manual
Intention of this manual
This information enables you to install and maintain your valve. This manual is for skilled
employees only. We assume that you are familiar with the common valve terminology and
that you can read technical documents.
If you don’t meet these expectations please inform your MIT customer advisor!
Latest documentation in the internet
Please check regularly for updated versions of this document. This manual is not audited
and represents only the current information of MIT at the time of pressure. You can get
current information of your product at any time in the internet: www.systemarmaturen.de.
Validity of the manual
We hereby declare that we reserve our right to modify both the manual and the valve if
necessary for technical advancement.
Attention! Please Danger!

read carefully Hot surface!
Danger!
Tools necessary
Voltage.
For your Please read

information documents
Attention! Hint to the

Risk of injury! manual part.
Supply items
needed!
-4-
BW-3Tlg-KH-H-Gw-05-01 ENGLISH
Intended usage
Hand lever ball valves of the types DKA04 and DKA07 made by MIT Armaturen GmbH are
suitable for the producing industries. The armatures make possible to distribute neutral
gaseous and liquid media. The housing and sealing compounds must be suitable for the
assigned medium and temperature range.
Danger of injury
Don´t put parts of your body or articles into the ball valve. This can cause heavy injuries
and should be absolutely avoided!
MIT-products are protected by packing against external influences such as humidity or dirt. We
recommend to remove this packing only briefly before beginning of assembly in order to protect the
devices against impurities.
During storage it is to be made certain that the devices are dry and dirt-free accommodated.
After a long period of storage the breakaway torque may increase.

After opening and closing the ball valve manually for one time the rated breakaway torque can be
reached again
On the handling in case of transport we can take influence however only with your assistance -
please inform us immediately if the commodity already arrives you with damaged packing! An
eximination of the technical parameters an a visual check of the product should take place
emidiately after delivery. Subsequently possible complains will not be excepted.
The warranty expires if product failings or quantity divergences are not announced in writing
within 7 days after receipt of goods!
Please ensure that no humidity gets into the pipings. Automated valves need a special attention in
time of initial operation! These devices can be tested at MIT only under workshop conditions.
Security positions should be simulated and tested straight. The final positions must be
checked(opened/closed) and be preadjusted if necessary! Additional switches or other electric
devices to the position feedback must be likewise checked for correct alignment.
-5-
Device description
1. nut
2. hand lever
3. spindle (assembly from down)
4. body screw
5. gland
6. bodyseal
7. ball
8. wearing part
9. caps
10. body nut
11. body seal
12. body
13. thrust ring
14. gland seals (3 pcs.)
15. wearing part
Maintenance
Before the ball valve can be serviced, all in- and outputs must be switched without
pressure. With reassembly of the ball valv pay attention to the fact that the body screws
are drawn firmly and overcross!
The following maintenance reasons are possible:
Problem Possible cause Solution

Change sealing
undensity Defective seal
compound
Undensity at the
Gland nut loose Fix the gland nut
spindle
Clean the ball / ball
Ball valve treacly Soiling of the ball
valve
-6-
Activity description
Installation of a ball valve with thread connection
The installation may occur only in state without pressure. Abuse with
the assembly the hand lever not as a lever!
Fix the ball valve carefully into a vice stretch, (use protection
cheeks to prevent damages of the body) loose the screws
crosswise and take them out.
Please pay attention to the fact that the used sealing compounds means are suitable for
the flowing medium!
Take out carefully the ball valve center section, respect that the
seals or the ball do not fall out.
Attach suitable sealing compounds to the

conduit ends, if you use PTFE tape or hemp
seal follow the direction of thread.
Use only to the purpose suitable
sealing compunds.
Fix the caps on the pipe ends and install the ball valve.
Fix body screws firmly and crosswise.
-7-
BW-3Tlg-KH-H-Gw-05-01
Kontakt / Contact:
MIT Armaturen GmbH

Industriestr. 9
32602 Vlotho
Tel. +49 (5228) 952-0
Fax +49 (5228) 950-90
Email: MIT@Systemarmaturen.de
Internet: www.systemarmaturen.de
-8-
Einteilig handbetriebene Kugelhähne
One piece ball valve with hand lever DEUTSCH
ENGLISCH

Installation and Maintenance
Bitte lesen Sie vor Installation Ihrer Armatur diese Betriebs- und Wartungsanleitung sorgfältig
durch.
Die Installation und Wartung darf nur durch qualifiziertes Personal durchgeführt werden.
Bitte beachten Sie die in dieser Anleitung aufgeführten Sicherheitshinweise!
Before installing and maintaining your valve, read this manual carefully.
Installation and maintanance is allowed for skilled employees only.
Please pay attention to the safety advices!

©2005 - MIT Armaturen GmbH, Vlotho
Alle Rechte an Texten und Bildern, auch die der Übersetzung, sind vorbehalten.
Dieses Handbuch darf nicht, auch nicht in Auszügen, in irgendeiner Form (Druck, Fotokopie, Mikrofilm oder weitere
Verfahren) ohne schriftliche Zustimmung reproduziert oder unter Verwendung elektronischer Systeme verarbeitet,
vervielfältigt oder verbreitet werden.
The property rights of all texts and pictures are subject to MIT Armaturen GmbH. It is not allowed to change or duplicate
even parts of it without written permission. We do not assume responsibility for correctness and integrity. Colours of
original products can differ from images.
Änderungen sind vorbehalten.

Errors excepted regarding print and technical changes.
Auflage: April 2005, Revision 1

Edition: April 2005 Revision 1
Anfragen richten Sie bitte schriftlich an:

MIT Armaturen GmbH
Industriestr. 9
32602 Vlotho
-2-
Inhaltsverzeichnis
Seite / page
Zu dieser Anleitung 4
This manual
Abkürzungen und Symbole 4
Leistungsbeschreibung 5
Bestimmungsgemäße Verwendung 5
Intended usage
Lagerung, Transport, Entsorgung 5
Allgemeine Einsatzbedingungen 5
Gerätebeschreibung 6
Device description
Wartung 6
Maintenance
Inbetriebnahme und Wartung 7

Acticity description
Installation und Inbetriebnahme 7
Installation
-3-
DEUTSCH BW-1Tlg-KH-H-Gw-05-01
Zu dieser Anleitung
Ziel der Anleitung
Die vorliegenden Informationen ermöglichen es Ihnen, die Armatur fachgerecht zu

installieren und zu warten.
Die Anleitung richtet sich an technisch qualifiziertes Personal. Es wird vorausgesetzt, dass
bestimmtes Fachvokabular verstanden wird und dass technische Zeichnungen gelesen
werden können.
Sollte dies nicht der Fall sein, informieren Sie bitte Ihren zuständigen Kundenbetreuer
bei MIT.
Aktuelle Dokumentation im Internet
Wir bitten Sie, sich regelmäßig über aktualisierte Versionen dieser Anleitung zu informieren.
Diese Anleitung unterliegt nicht der Revisionierung und stellt lediglich den zum Zeitpunkt
des Drucks aktuellen Informationsstand der MIT Armaturen GmbH dar. Aktuelle
Informationen zu Ihrem Produkt können Sie jederzeit unter www.systemarmaturen.de
abrufen.
Gültigkeit der Anleitung
MIT Armaturen behält sich Änderungen an der Armatur sowie Erweiterungen und
Änderungen der vorliegenden Anleitung, die dem technischen Fortschritt dienen, vor.
Achtung! Bitte Achtung! Heiße

lesen! Oberfläche!
Werkzeug Vorsicht!
notwendig Spannung
Zu Ihrer Dokumente

gefahr! Anleitung
Betriebsstoff
notwendig
-4-
BW-1Tlg-KH-H-Gw-05-01 DEUTSCH
Hanbetätigte Kugelhähne der Baureihen NKA01, NKA04, NKA51, NKB01, NKB04, NKB51,
EKA08, EKA05 und SKA53 der MIT Armaturen GmbH sind zum Einsatz im industriellen
Bereich geeignet. Die Armaturen ermöglichen das Absperren gasförmig- und flüssiger
Medien. Die Gehäuse- und Dichtmaterialien müssen für das eingesetzte Medium geeignet
sein.
Verletzungsgefahr
Hineinführen von Körperteilen und Gegenständen in den Kugel-

hahn kann zu schweren Verletzungen führen und sollte unbe-
dingt vermieden werden!
MIT-Produkte sind i.d.R. durch Umverpackungen vor äußeren Einflüssen wie Feuchtigkeit oder
Schmutz geschützt. Wir empfehlen, diese Umverpackung erst kurz vor Montagebeginn zu
entfernen, um die Geräte vor Verunreinigungen zu schützen.
Bei Einlagerung ist darauf zu achten, dass die Geräte trocken und schmutzfrei untergebracht
werden.
Lange Lagerzeiten können eine Erhöhung des Losbrechmomentes zu Folge haben. Erst nach
Betätigung des Kugelhahns wird das Nenndrehmoment wieder erreicht.
Auf die Handhabung beim Transport können wir jedoch nur mit Ihrer Hilfe Einfluss nehmen – bitte
informieren Sie uns unverzüglich wenn die Ware bereits mit beschädigter Verpackung bei Ihnen
eintrifft! Die Kontrolle der Produkte muss unmittelbar nach Wareneingang erfolgen und sollte eine
Prüfung der technischen Parameter und eine Sichtprüfung beinhalten. Verdeckte Mängel sind
unverzüglich nach Entdeckung zu rügen, andernfalls gilt die Ware als genehmigt.
Warenmängel oder Abweichungen der Menge müssen spätestens

7 Tage nach Erhalt der Ware schriftlich angezeigt werden, andernfalls
erlischt der Gewährleistungsanspruch!
Rohrleitungen sollten vor Einbau, spätestens jedoch vor Inbetriebnahme durchgespült werden.
Automatisierte Armaturen bedürfen einer besonderen Beachtung bei der Inbetriebnahme! Diese
Geräte können im Werk nur unter Werkstattbedingungen getestet und eingestellt werden.
Sicherheitsstellungen sollten gezielt simuliert und getestet werden. Die Endlagen
(offen/geschlossen) müssen überprüft und ggf. nachjustiert werden! Zusätzliche Wegschalter oder
andere elektrische Geräte zur Stellungsrückmeldung ebenfalls auf richtige Justierung überprüfen!
-5-
DEUTSCH BW-1Tlg-KH-H-Gw-05-01
Gerätebeschreibung
Spindel
Handhebel
Mutter
Stopfbuchsmutter
Anschluss
Gehäuse
Wartung
Einteilige Kugelhähne sind Wartungsfrei.
Folgende Probleme können auftreten:
Fehler Mögl. Ursache Abhilfe

Stopfbuchsmutter Stopfbuchsmutter nach
Undichtigkeit
gelöst ziehen
Kugel durch
Bitte setzen Sie sich mit
Medium/Schmutz in
Undichtigkeit ihrem Servicepartner in
den Leitungen
Verbindung
verschlissen
Kugelhahn Verschmutzung der Reinigen der Kugel /
Schwergängig Kugel des Kugelhahns
Wir empfehlen ihnen, bei einem defekten einteiligen Kugelhahn die ganze Armatur aus zu tauschen!
-6-
BW-1Tlg-KH-H-Gw-05-01 DEUTSCH
Installation und Inbetriebnahme eines Kugelhahns mit Gewindeanschluss

Missbrauchen Sie bei der Montage den Handhebel nicht als Hebel!
Zum Anschluss des Kugelhahns an Ihr Rohrsystem benötigen Sie eine Schlüsselweite
von X mm.
Geeignetes Dichtmaterial an die Rohrleitungsenden anbringen, bei PTFE-Band

oder Hanfdichtungen die Einschraubrichtung beachten.
Nur dem Einsatzzweck entsprechende Dichtmaterialien verwenden
Bitte achten Sie darauf, dass das verwendete Dichtmittel für das Durchlfuss-Medium
geeignet ist!
Rohrleitungsenden in Gewindeenden des Kugelhahns einschrauben dabei nur

die Schlüsselflächen des Kugelhahnes, nicht den Handhebel benutzen!
Aushärtezeit des Dichtmaterials abwarten erst dann die Rohrleitung mit

Druck beaufschlagen.
-7-
This manual
This information enables you to install and maintain your valve.

This manual is for skilled employees. We assume that you are familiar with the common
valve terminology and that you can read technical documents.
If you don’t meet these expectations please inform your personal customer advisor!
Latest documentation in the internet
Please check regularly for updated versions of this document. This manual is not audited
and represents only the current information of MIT at the time of pressure. You can get
current information of your product at any time in the internet: www.systemarmaturen.de.
Duration of validity
We hereby declare that we reserve our right to modify both the manual and the valve if
necessary for technical advancement.
Attention! Please Danger!

read carefully Hot surface!
Danger!
Tools necessary
Voltage.


Supply items
needed!
-4-
Intended usage
Hand lever ball valves of the series NKA01, NKA04, NKA51, NKB01, NKB04, NKB51,
EKA08, EKA05 and SKA53 made by MIT Armaturen GmbH are suitable for the producing
industries. The valves makes possible to distribute and mix neutral gaseously and neutral
liquid media. The housing and sealing compounds must be suitable for the assigned
medium and temperature range.
Danger of injury
Don´t put parts of your body or articles into the ball valve. This can cause heavy injuries
and should be absolutely avoided!
MIT-products are protected by packing against external influences such as humidity or dirt. We
recommend to remove this packing only briefly before beginning of assembly in order to protect the
devices against impurities.
During storage it is to be made certain that the devices are dry and dirt-free accommodated.
After a long period of storage the breakaway torque may increase.

After opening and closing the ball valve manually for one time the rated breakaway torque can be
reached again
We can only take influence on the transport process with your assistance - please inform us
immediately if the commodity arrives with damaged packing! Examination of technical parameters
and a visual product check should take place emidiately after delivery. Subsequent complains can
not be excepted.
Goods faults or divergences of the amount must be indicated at the latest 7 days on receipt of
the product in writing, otherwise the guarantee claim goes out!
Please ensure that no humidity gets into the pipings. Automated valves need a special attention in
time of initial operation! These devices can be tested at MIT only under workshop conditions.
Security positions should be simulated and tested straight. The final positions must be
checked(opened/closed) and be preadjusted if necessary! Additional switches or other electric
devices to the position feedback must be likewise checked for correct alignment.
-5-
Device description
Spindle
Hand Lever
Nut
Gland Nut
Thread
Body
Maintenance
One-piece ball valves are maintenance-free.
The following problems are possible:
Problem Possible cause Solution

Change sealing
undensity Defective seal
compound
Undensity at
Gland nut loose Fix the gland nut
the spindle
Ball valve Clean the ball / ball
Soiling of the ball
treacly valve
We recommend you to exchange the whole armature if the ball balve is defective.
-6-
Activity description
Installation of a ball valve with thread connection
The installation may occur only in state without pressure. Abuse with the assembly the
hand lever not as a lever!
To the connection of the ball valve with your pipe system you need a spanner width from X
mm...
Attach suitable sealing compounds to the pipe ends, if you use PTFE tape or
hemp seals follow the direction of thread.
Use only to the purpose suitable sealing compound.
Please pay attention to the fact that the used sealing compounds means are suitable for
the flowing medium!
Screw pipe ends in thread ends of the ball valve, only use the spanner surfaces
of the ball valve, do not use the hand lever!
Do not give pressure on the piping when the sealing material is not
hardened .
-7-
Kontakt / Contact:
MIT Armaturen GmbH

Industriestr. 9
32602 Vlotho
Tel. +49 (5228) 952-0
Fax +49 (5228) 950-90
Email: MIT@Systemarmaturen.de
Internet: www.systemarmaturen.de
-8-
Westfalia Separator
Straight through control valves - STEVI® 440 / 441, 445 / 446
Series 440, 445 Series 441, 446
Contents
1.0 General information on operating 7.0 Care and maintenance................................... 6
instructions ..................................................... 2 7.1 Replacement of stem sealings ............................... 6
2.0 Notes on possible dangers............................ 2 7.1.1 PTFE V-ring unit design ..................................... 6
2.1 Significance of symbols ..........................................2 7.1.2 Stuffing box packing design ............................... 7
7.1.3 Bellows seal design ........................................... 8
2.2 Explanatory notes on safety information .................2
7.2 Tightening torques.................................................. 8
3.0 Storage and transport ................................... 2 7.2.1 Tightening torques for hexagon nuts ............... 8
4.0 Description...................................................... 3 8.0 Troubleshooting ............................................. 8
4.1 Scope of applications ..............................................3
9.0 Troubleshooting table .................................. 9
4.2 Operating principles ................................................3
10.0 Dismantling the valve or the top part ...... 10
4.3 Technical data .........................................................3
4.4 Marking ...................................................................3
5.0 Installation....................................................... 4
5.1 General notes on installation...................................4
5.2 Requirements at the place of installation ................5
5.3 Installation instructions concerning actuators .........5
6.0 Putting the valve into operation.................... 6
Rev. 0040301002 2608 englisch

Str. thr. control valves - STEVI® 440 / 441, 445 / 446

and repair.
ATTENTION !

to property.

ATTENTION !
- At -20°C to +65°C.
Page 2 Rev. 0040301002 2608

4.0 Description
Valves are used for „controlling the flow of liquids, gases and vapours in chemical and other
processing plants and for plant engineering“.
ATTENTION !
state the higher requirements when ordering.
to TRD 110.

The control valves are especially suitable for actuation by electrical actuators.
The flow through control valves is always against the closing direction.
4.3 Technical data
for
- Pressure-temperature-ratings, etc. refer to data sheet.
4.4 Marking
Nominal diameter Manufacturer
Type-Number CE-marking
Flow Nominal pressure
characteristic Notified body
Kvs-value
Plug Customer-specific
design information
Serial-No. Stem sealing
Material of Year of manufacture clear speech
internal parts (1. and 2. position)
Fig. 1
According to the Pressure Equipment Directive table 6, annex II, valves without safety
function are only allowed to bear the CE-marking DN32 onwards.
Rev. 0040301002 2608 Page 3

5.0 Installation
The following items should be taken into account besides the general principles governing
installation work:
ATTENTION !
- The interior of valve and pipeline must be free from foreign particles.
- Note installation position with reference to flow, see mark on valve.
- Steam line systems should be designed to prevent water accumulation.
avoided.
Refer to data sheet for weights.
- Keep the thread and shaft of the stem free from paint.
- Centre gaskets between the flanges.
- Strainers or filters should be installed before the valves.
Planners / construction companies or operators are responsible for positioning and

Page 4 Rev. 0040301002 2608

5.2 Requirements at the place of installation
The place of installation should be easily accessible and provide ample space for
maintenance and removing the actuator. Stop valves should be installed before and after
the control valve to enable maintenance working without draining the piping system. The
valve should preferably installed vertically with the actuator at the top. Inclined or horizontal
installation without supports is permissible only with light actuators.
For this installation position, the two distance columns (or joke) have to be above each
other in the vertical plane.
Fig. 2: Pipeline vertically Fig. 3: Pipeline horizontally

Permissible actuator weights for valves with unsupported horizontal stems:
20 kg for DN 15 - 32
25 kg for DN 40 - 65
35 kg for DN 80-100
40 kg for DN125-150
The pipes must be lagged to protect the actuators from excessive heat. Sufficient space
must be left for the maintenance of the stem packing.
To ensure that the control valves function correctly, the pipe run should be straight for at
least 2 x n.d. upstream and 6 x n.d. downstream of the valve.
5.3 Installation instructions concerning actuators

Normally, control valves are supplied complete with actuator fitted.
It is not permitted to mantle / dismantle actuators with valves operating and service
conditions (temperature and pressure). The actuators must be assemble as describe in the
operating instructions during conversion and maintenance.
During assembly work, the plug is not be turned on its seating at closing pressure.
ATTENTION !
Care must be taken with the bellow type valves when actuators are mounted or
removed. (Hold the valve-stem against turning with an open-end wrench!)
When retrofitting actuators, the maximum permissible force for valve actuation must be
taken into account:
Series 440 / 445 Series 441 / 446
12kN for DN 15- 50 18kN for DN 15-100
29kN for DN 65-100 37kN for DN 125-150
40kN for DN125-150
Rev. 0040301002 2608 Page 5


ATTENTION !
- Touching the valve when it is operating at high (> 50 °C) or low (< 0 °C) media
Maintenance and maintenance intervals have to be defined by the operator according to
the service conditions.
7.1 Replacement of stem sealings

7.1.1 PTFE V-ring unit design
PTFE V-ring unit (pos. 12) consisting of:
1 backing ring
4 sealing rings
1 cover ring
Owing to the installed compression spring (pos. 15), this
stem packing is self-adjusting. If the stem starts leaking,
the ring pack is worn out and must be replaced.
Replacement of PTFE V-ring units:
ATTENTION !
Refer to item 10.0 before dismantling the
valve.
- Remove actuator.
(Refer to operating instructions for actuator!)
- When replacing PTFE V-ring unit (pos. 12), make sure
that the parts are installed in the correct order and
positions (refer to Fig. 4).
- Gasket (pos. 17) must be replaced.
If the stem is damaged, the valve must be replaced since
a new ring pack will soon start leaking again if the stem is
damaged. Fig. 4:
Page 6 Rev. 0040301002 2608

7.1.2 Stuffing box packing design
- The stuffing box packing (pos. 23) requires maintenance.
- If leaks develop, immediately tighten the screw joint (pos. 25) gradually until the packing
(pos. 23) stops leaking.
- The service life of stuffing box packings (pos. 23) can be increased by checking regularly
leakage.
- If leaks can no longer be stopped by tightening the screw joint (pos. 25), a new packing
ring (pos. 23) must be inserted into the gland.
Replacement of stuffing box packings:
ATTENTION !
Refer to item 10.0 before dismantling the valve.
- Remove actuator. (Refer to operating instructions for actuator!)
- Insert new packing ring as shown in Fig. 5 - Fig. 6.
Fig. 5: Stuffing box packing
If a split packing ring is used, cut with a chamfer

as shown in Fig. 6.
Fig. 6: Split packing ring

If the stem is damaged, the valve must be replaced since a new ring pack will soon start
leaking again if the stem is damaged.
Rev. 0040301002 2608 Page 7

7.1.3 Bellows seal design
If the stem leaks, the bellows seal is defective. The leak can initially be stopped by
tightening the screw joint.
Afterwards the valve must be replaced.
7.2 Tightening torques

7.2.1 Tightening torques for hexagon nuts
M 10 = 15 - 30 Nm
M 12 = 35 - 50 Nm
M 16 = 80 - 120 Nm
! Refer to operating instructions for actuator concerned for

installing actuators !
8.0 Troubleshooting
Instructions.
ATTENTION !
- It is essential that the safety regulations are observed when identifying faults.
-

“9.0 Troubleshooting table”, the supplier or manufacturer should be consulted.
Page 8 Rev. 0040301002 2608


ATTENTION !
- read item 10.0 prior to dismantling and repair work!
- read item 6.0 before restarting the plant !

No flow Valve closed. Open valve (using actuator).
Flange covers not removed. Remove flange covers.
Little flow Valve not sufficiently open. Open valve (using actuator).
Dirt sieve clogged. Clean / replace sieve.
Piping system clogged. Check piping system.
Kvs value of valve unsuitable. Fit valve with higher Kvs value.
Valve stem moves in jerks. Stuffing box sealing too tight Slacken screw joint slightly. Valve
(for valves with graphite packings). must nor start leaking!
Valve stem or plug cannot be Valve plug seized in seating or guide Replace valve
moved. owing to deposits or dirt in medium.
Valve stem leaking. PTFE V-ring unit damaged or worn. Replace ring pack (pos. 12);
refer to item 7.1.1
Stuffing box gland too slack in valves Tighten screw joint (pos. 25);
with stuffing box packings. refer to item 7.1.2.
Bellows defective in valves with bellow Replace valve
seal.
Leakage too high when Sealing surfaces of plug eroded or Replace valve
valve is closed. worn.
Sealing edge of seating damages or Replace valve
worn.
Rev. 0040301002 2608 Page 9


ATTENTION !
media.
Westfalia Separator
Customer Support Center
Am Neuländer Gewerbepark 6
21079 Hamburg (Germany)
Phone +49 40 58 96 500

Fax +48 40 73 80 585
Mail to: info@gea-westfalia.de
Page 10 Rev. 0040301002 2608

Operating and Installation Instructions
Thrust actuator ARI-PREMIO
Contents
1.0 General information on operating instructions...................................................................................... 3
2.0 Notes on possible dangers ...................................................................................................................... 3
2.1 Significance of symbols ......................................................................................................................... 3
2.2 Explanatory notes on safety information ................................................................................................. 4
3.0 Storage and transport............................................................................................................................... 4
4.0 Description ................................................................................................................................................ 5
4.1 Field of application .................................................................................................................................. 5
4.2 Method of functioning.............................................................................................................................. 5
4.3 Diagram .................................................................................................................................................. 6
4.3.1 ARI-PREMIO 2,2 - 5 kN........................................................................................................................ 6
4.3.2 ARI-PREMIO 12 - 15 kN....................................................................................................................... 7
4.3.3 Parts list................................................................................................................................................ 8
4.4 Technical data ......................................................................................................................................... 9
4.5 Dimensions ............................................................................................................................................11
5.0 Installation .............................................................................................................................................. 12
5.1 General installation data ....................................................................................................................... 12
5.2 Manual operation .................................................................................................................................. 14
5.2.1 ARI-PREMIO 2.2 - 5 kN ..................................................................................................................... 14
5.2.2 ARI-PREMIO 12 - 15 kN .................................................................................................................... 15
Rev. 0040501000 2607 englisch

5.3 Installation instructions for mounting to valves...................................................................................... 16
5.3.1 Mounting for valve-lift up to 30 mm (yoke version)............................................................................. 16
5.3.2 Mounting for valve lift over 30 mm to 80 mm (column version) .......................................................... 18
5.4 Electrical connection ............................................................................................................................. 20
5.4.1 Wiring diagram ARI-PREMIO 2.2 - 5 kN ............................................................................................ 20
5.4.2 Wiring diagram ARI-PREMIO 12 - 15 kN ........................................................................................... 21
5.4.2.1 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ without reversing contactor............................................................. 21
5.4.2.2 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ with reversing contactor.................................................................. 22
5.4.3 Connection ........................................................................................................................................ 23
5.5 Settings ................................................................................................................................................ 24
5.5.1 Torque and travel switches ................................................................................................................. 24
5.5.2 Connection boards PA or NA (only 2.2 - 5 kN) ................................................................................... 24
5.5.3 Travel switch....................................................................................................................................... 25
5.5.3.1 Installation of additional travel switches......................................................................................................... 25
5.5.3.2 Installation and setting of the travel switch (S3) ............................................................................................ 27
5.5.3.3 Setting the additional travel switches (S4/S5 and S24/S25).......................................................................... 28
5.5.4 Potentiometers ................................................................................................................................... 29
5.5.4.1 Installing the potentiometer............................................................................................................................ 29
5.5.4.2 Setting the potentiometer............................................................................................................................... 31
5.5.5 Error-proof potentiometer for single-channel, error-proof position feedback..................................... 32
5.5.5.1 Setting the potentiometer on conductive plastic basis................................................................................... 32
5.5.6 Heating ............................................................................................................................................... 34
5.5.6.1 Installation of heating..................................................................................................................................... 34
5.5.7 Electronic position indicator RI21 ....................................................................................................... 35
5.5.8 Electronic position controller ES11 ..................................................................................................... 35
5.5.9 Electronic position indicator (RI21) and position controller (ES11) together in the actuator............... 36
5.5.10 Integrated temperature controller dTRON 316 ................................................................................. 37
5.5.10.1 Installation of the dTRON 316 ..................................................................................................................... 37
5.5.11 Integrated reversing contactor .......................................................................................................... 38
5.5.11.1 Installing the reversing contactor ................................................................................................................. 38
5.5.11.2 Electrical connection with ES11 or dTRON 316........................................................................................... 38
5.5.12 Phase control relay........................................................................................................................... 39
5.5.12.1 Installing the phase control relay ................................................................................................................. 39
5.5.13 DC-MODULE.................................................................................................................................... 40
5.5.13.1 Fitting the DC MODULE to ARI-PREMIO .................................................................................................... 40
5.5.13.2 Technical data - DC-Module ........................................................................................................................ 42
5.5.13.3 Wiring diagram ARI-PREMIO 2.2 - 5 kN + 3-step DC module ................................................................... 43
5.5.13.4 Wiring diagram ARI-PREMIO 2.2 - 5 kN + DC module .............................................................................. 44
5.5.14 Electronic position indicator RI32 ..................................................................................................... 45
5.5.14.1 Useful range of the linear motion potentiometer ......................................................................................... 45
5.5.14.2 Installing the RI32 electronic position indicator in the PREMIO................................................................... 45
5.5.14.3 Electronic position indicator (RI32) and position controller (ES11) together in the actuator........................ 46
5.5.14.4 Technical data - Position indicator RI32....................................................................................................... 47
5.5.14.5 Potentiometer installation ........................................................................................................................... 47
5.5.14.6 Wiring diagram ............................................................................................................................................ 48
5.5.14.7 Connection conditions ................................................................................................................................. 48
5.5.14.8 Setting zero point and slope span ............................................................................................................... 49
6.0 Putting the actuator into operation ...................................................................................................... 50
7.0 Care and maintenance............................................................................................................................ 50
8.0 Troubleshooting ...................................................................................................................................... 50
9.0 Troubleshooting table ............................................................................................................................ 51
10.0 Dismantlement of thrust actuator ....................................................................................................... 52
11.0 Warranty / Guarantee ............................................................................................................................ 52
12.0 EC declaration of conformity ............................................................................................................... 53

and repair.
ATTENTION !
ATTENTION !
... Warning of dangerous voltage.
Exposed to injury!
Don’t touch the turning handwheel when the motor is running.
Exposed to injury!
Don’t put your hand into the up or downwards moving
appliance.
Danger when not observing the operating and installation

instructions!
Before installing, operating, maintenance or dismantling read
and observe the instructions.
Danger though voltage!

Before dismantling the hood, switch of the electrical source
and secure against turning on again.
0040501000 2607 Page 3


to property.

ATTENTION !
- Valve mountings such as drives, handwheels, hoods must not be used to take
external forces, e.g. they are not designed for use as climbing aids, or as
Non-compliance may lead to death, injury or damage to property due to
persons falling or parts being dropped.
See “4.4 Technical data” for weights.
- At -20° to +70°C dry, free from dirt.

- Do not unpack thrust drive or setting equipment assembly prior to installation.
- Protect against external force (impact, vibration etc.).
- Do not soil or damage type identification plate and wiring diagram on the controller.
Page 4 0040501000 2607

4.0 Description
4.1 Field of application
ARI-PREMIO linear thrust actuators are employed to actuate control or shut-off valves
requiring a nominal linear stroke distance of up to 80 mm and thrust from 2.2 kN to 15 kN.
The thrust actuators are set to the thrust forces specified in the technical data. If supplied
with the valve, the lift of the thrust actuator will be set to the stroke distance of the valve.
Selection of the proper actuator version in alignment with the corresponding fitting as well
as use of the thrust actuator in accordance with the specified technical data is the
responsibility of the systems engineer.
See data sheet for areas of application, application limits and potential.
Any use of the thrust actuator beyond the specified technical data or improper use of the
actuator is deemed to be not for the intended purpose.
The ambient conditions have to be conform to the actual electromagnetic compatibility
directives. Additional the compatibility to this directives has to be maintained in case of
expansion or other changing of the ambient conditions.
4.2 Method of functioning

The thrust actuator, fitted with a yoke or columns, is mounted to the valve.
Transfer of force is effected via a coupling safeguarded against torsion.
The torsion safeguarding feature also serves as a lift indicator.
The lift settings can be read off on a lift dial attached to the yoke or between the 2-ear
clamps mounted to the column.
The electrical components are accommodated separately from the gearbox underneath a
sealed hood, thus being protected against operating and environmental effects.
Following removal of the hood, easy access is provided to the switchgear and indicating
feature.
The rotary motion of the motor is transmitted to the spindle nut by means of spur gear.
The drive spindle, which is safeguarded against torsion, screws its way into the spindle nut
and thus performs a pull or push motion depending on the sense of rotation.
In the final positions of the valve, the spindle nut is pressed against a set of springs so as to
produce closing force.
The motor is switched off by means of two load-dependent switches and one stroke-
dependent switch. The load-dependent switches will also switch off the motor if foreign
bodies have lodged themselves between the valve seat and cone.
The load-dependent switches serve to protect the valve and thrust actuator against
damage.
0040501000 2607 Page 5

4.3 Diagram
4.3.1 ARI-PREMIO 2,2 - 5 kN
Yoke Version Column Version
Fig. 1
Page 6 0040501000 2607

4.3.2 ARI-PREMIO 12 - 15 kN
Fig. 2
0040501000 2607 Page 7

4.3.3 Parts list
Pos. Designation Pos. Designation

50.1 Gearbox 50.30 Driving spindle
50.1.1 Gearbox cover plate 50.31 Spindle safety feature
Cable gland 50.32 Torsion safety feature
2.2 - 5kN: 2 x M16x1,5 50.34 Bellow
50.2
12 - 15kN: 2 x M16x1,5 /
1 x M20x1,5 50.35 Grub screw DIN ISO 4766 - M6
50.4 Sealing plug 1 x M16x1,5 50.36 Set collar
50.6 Hood 50.37 Grub screw DIN 913-M3x5
50.7 Hood seal 50.40 Synchronous motor, complete
50.8 Counter-sunk screw DIN EN ISO 50.40.3 Motor capacitor
10642 - M5x20
50.9 Sealing washer DIN EN ISO 7089 50.41 Head cap screw
DIN EN ISO 4762-M4 - 18
50.10 Column 50.42 Board support
50.11 Conical spring washer 50.43 Standard board
50.12 Handwheel 50.43.1 Directional switch (valve – up) S3
50.12.1 Turning handle of handwheel 50.43.2 Torque switch
50.14 Yoke 50.45 Shift lever
50.15 Flange 50.46 Washer
50.16 Spring washer DIN 128-A10 50.47 Wiring diagram sticker, standard
50.17 Hexagon head screw 50.48 Connector, 3-pole (standard)
DIN EN ISO 4017 - M10x40
50.18 Hexagon head screw 50.57 Head cap screw
DIN EN 24017-M10x55 DIN EN ISO 4762 - M4x10
50.19 T-head bolt DIN 261-M12x40 50.58 Protective conductor terminal
50.20 Washer DIN EN ISO 7089 50.59 Head cap screw
50.21 Spring washer DIN 128-A12 50.87 Threaded bush
50.22 Hexagon nut DIN EN ISO 4032 - M12 50.96 O-ring DIN 3771 – 4 x 1.8
50.23 Lift dial 50.101 Connector, 8-pole
50.24 Distance column 50.110 Gear cap
50.25 Hexagon nut DIN 980-V-M16 50.115 O-ring DIN 3771 - 52x2.5
50.26 2-ear clamp (stroke indicator) 50.119 Fan wheel
50.27 Coupling
Page 8 0040501000 2607

4.4 Technical data

Type ARI-PREMIO
Thrust force kN 2,2 5,0 12,0 15,0
Stroke distance max. mm 50 80
Duty classification acc. to EN 60034-1/A11 S3 80% 1200 c/h S3 50% 1200 c/h
Control speed mm/sec. 0.38 0.38 1,0 0.79 0.38
Motor voltage 230V - 50Hz / 60Hz 1) 230V - 50Hz
Power consumption W 11.7 25.3 52.9 109 96

Torque switch 2 pcs., permanently wired, 2 pcs., permanently wired
switching capacity 10A, 250V~ switching capacity 16A, 250V~
Travel switch 1 pcs., permanently wired, 1 pcs.,
switching capacity 10A, 250V~ permanently wired
switching capacity 16A, 250V~
Enclosure IEC 60529 IP 65
Max. permissible ambient temperature -20 °C ... +70 °C
Handwheel Yes (rotating during operation) Yes (engageable)
Mounting position Any. Exception: motor must not be suspended downwards
Gear lubricant Molyduval
Klüber Isoflex Topas NB152
Valenzia H2
Weight kg 5.4 6 6.5 10.5
1)
Control speed and power consumption are 20% higher at frequency of 60 Hz
0040501000 2607 (Rev.2) Page 9

Accessories
Type ARI-PREMIO
Thrust force kN 2,2 5,0 12,0 15,0
Trip slide for travel switche S3 for actuating travel switch S3 / retracting spindle
(the travel switch S3 exists in the standard version)
Additional intermediate position switches 2 additional intermediate position switches, zero potential,
S4, S5 2) Switching capacity 10A, 250V ~
Additional intermediate position switches 2 additional intermediate position switches, zero potential, with gold contacts, for low
for low-voltage / electronic system switching capacities and at aggressive atmosphere,
S4, S5 2) switching capacity max. 0.1A, 4-30V
Potentiometer 2) max. 2 only Ohmage optional: 100, 200, 500, 1000, 1000 Ohm; 1,5 Watt
max. 2 only - Ohmage 5000
or optional: 100, 200, 500, 1000 Ohm; 1,5 Watt;
TÜV-approved potentiometer 2) Not compatible for use with the heating resistor or RI21!
No retrofitting possible!
0(2) ... 10V . 0(4) ...20mA, Only 1 potentiometer possible
Electronic position controller ES 11 2)
Not compatible for use with the temperature controller.
0(2) ... 10V . 0(4) ...20mA, Only 1 potentiometer possible
Electronic position indicator RI 21 2)
Using the temperature controller, installation is only possible in the control cabinet
Electronic position indicator RI32 2) 2... 10V; 4... 20 mA Only 1 potentiometer possible.
Heating resistor (with automatic switching) 230V-50Hz, 115V-50Hz, 24V-50Hz, 15 Watt
24V - 50Hz
24V - 50Hz 24V - 60Hz 1)
24V - 60Hz 1) 115V - 50Hz
24V - 50 / 60Hz 1)
Additional voltages / frequencies 115V - 50Hz 115V - 60Hz 1)
115V - 50 / 60Hz 1) 115V - 60Hz 1) 230V - 60Hz 1)
230V - 60Hz 1) 3~400V - 50Hz
3~400V - 60Hz 1)
Standard-voltage connection board, PA 2 torque switches and 1 travel switch, zero potential, Possible
for free wiring, with standard
Switching capacity10A, 250V ~ version
Low-voltage connection board (electronic 2 torque switches and 1 travel switch,
system), NA for free wiring, with gold contacts,
for low switching capacities and at aggressive atmosphere.
Switching capacity max. 01A, 4-30V
Integrated temperature-controller Three-step temperature-controller in microprocessor-technology.
dTRON 316 Control range: -200°C to 850°C (resistance thermometer)
Voltage: 24V, 115V or 230V 50/60Hz
Compatible with resistance thermometers and thermocouples
(provided by customer), or standardized active current or voltage signals.
Not compatible for use with the ES11!
Actuator with 400V-50Hz and
Integrated reversing contactor -- 440V-60Hz
Only 1 electronic module possible!
Only in addition with integrated
Phase control relay --
reversing contactor!
To control ARI-PREMIO 230V-50Hz with 24VDC.
DC-Module
Not compatible for use with the --
3-step converter
temperature controller!
1)
Control speed and power consumption are 20% higher at frequency of 60 Hz
2)
Option trip slide necessary
Page 10 0040501000 2607 (Rev.2)

Fig. 3
Clearance required for
removal of hood
4.5 Dimensions

removal of hood
removal of hood
0040501000 2607
X L h
236 633 max. 30 mm
256 653 max. 50 mm
271 668 max. 65 mm
286 683 max. 80 mm
ARI-PREMIO 2.2 - 5 kN ARI-PREMIO 2.2 - 5 kN ARI-PREMIO 12 - 15 kN

Nominal stroke max. 30 mm Nominal stroke > 30 mm - 50 mm Nominal stroke max. 80 mm
Page 11
5.0 Installation
ATTENTION !
- Work on electrical systems or equipment must only be carried out by qualified
electricians or by trained individuals under the guidance and supervision of a
qualified electrician in compliance with regional electrical safety requirements
and regulations.
- Valve mountings such as drives, handwheels, hoods must not be used to take
external forces, e.g. they are not designed for use as climbing aids, or as
Non-compliance may lead to death, injury or damage to property due to
persons falling or parts being dropped.
- Actuator components which rotate or move during operation are coloured red.
Crushing and injury hazard!
5.1 General installation data

- In addition to general installation guidelines, the following points are required to be
observed:
- Planners / construction firms and operators are responsible for positioning and installing
the products.
ATTENTION !
- A voltage is induced in the thrust actuator motor. This induction voltage may be
higher than the operating voltage.
- For this reason relays and electronic load relays for thrust actuator control
require a protective circuit. The contacts of unprotected relays may stick after a
while.
- This may result in reversed directions of rotation or defective switch-off
Recommended safety circuit for relays and electronic load relays:

Connect a varistor or RC module parallel to each relay point.
Varistor S10K385 to S10K460
RC module 100 Ohm / 100nF
Where relay points and electronic load relays are particularly sensitive a coil should be
connected in series additionally to each relay point.
Recommended coil:
Toroidal coil 2mH / 2A
- Contactors of 16A and upwards do not need a safety circuit.
- Check thrust actuator for damage prior to fitting.
Damaged parts must be replaced by original spares.
- Existing operating instructions for valve.
- Complete valve with crossarm.
- Valve cone approximately in mid lift position - on no account supported inside a seat!
- Electrical installation in accordance with current regional regulations.
- Conductor cross-section selected to correspond to the given drive power and existing line
length.
Page 12 0040501000 2607

- Mains fuse rating max. 6A.
- Circuit breakers in the plant to cut off the mains supply to the actuator.
- Conformity of technical data on thrust actuator with field conditions.
- Mains voltage in accordance with data specified on rating plate of thrust actuator.
- Thrust actuator complete with yoke or distance columns and coupling parts intended for
mounting to the corresponding valve.
- Ease of access to installation site.
- Adequate clearance space above the thrust actuator for removing the hood
(refer to point 4.5 Dimensions).
- Install where there is protection against high-energy heat radiation.
- The ambient temperature must be between -20°C and +70°C.

If installed outdoors, the thrust actuator must be provided with an additional cover to protect
against
- rain,
- direct insulation,
- dust.
In case of widely fluctuating ambient temperatures, high atmospheric humidity and
temperatures below the freezing point, your are recommended to install a heating resistor
to minimise condensation buildup in the actuator.
- Thrust actuator mountable in any position except in downward suspended position.
If installed with a horizontal connecting rod, the thrust actuator must be mounted so both
yoke legs or columns are on top of one another in the vertical plane (see Fig. 4 ).
Correct Incorrect
Fig. 4
0040501000 2607 Page 13

5.2 Manual operation

5.2.1 ARI-PREMIO 2.2 - 5 kN
ATTENTION !
- The handwheel always rotates during motor-driven operation (running
indicator). Never activate manual operation while the motor is running.
Injury hazard!
- In the manual operating mode pay careful attention in the final positions that the
handwheel is only turned to the point where the torque switch trips (audible
click) as otherwise damage will be caused to the thrust actuator! Since the
handwheel always follows during motor-driven operation (running indication),
never operate by hand while the motor is running - potential injury hazards!
With the motor in the stationary state, the thrust actuator can be run in the retracted and
extended state with the handwheel firmly meshed with the gear.
Proceed as follows:
- Swing out lever (pos. 50.12.1) from handwheel (pos. 50.12).
- Turning in clockwise direction --> extending spindle.
- Turning in counter-clockwise direction --> retracting spindle.
retracting spindle extending spindle
Fig. 5
Page 14 0040501000 2607

5.2.2 ARI-PREMIO 12 - 15 kN
ATTENTION !
- Do not attempt to engage manual operation until the motor has stopped.
Switching over while the motor is running may damage the thrust actuator.
- In the manual operating mode pay careful attention in the final positions that the
handwheel is only turned to the point where the torque switch trips (audible
click) as otherwise damage will be caused to the thrust actuator!
With the motor in the stationary state, the thrust actuator can be run in the retracted and
extended state with the engageable handwheel.
Proceed as follows:
- Fold the turning handle out of the handwheel (A)
- Turn the handwheel slightly and push in the engaging button for manual mode (B)
--> the button engages
- Turning in clockwise direction --> extending spindle
- Turning in counter-clockwise direction --> retracting spindle
The motor is no longer in mesh when the handwheel is engaged. The handwheel is
automatically disengaged when the motor starts and the motor is once more in mesh.
Engaging button
for manual mode
retracting
extending
Fig. 6
ATTENTION !
When changing the motor, it’s necessary to
observe for a correct function of the manual
operating device, that the head-cap screw
M4x18 is screwed in the right place.
0040501000 2607 Page 15

5.3 Installation instructions for mounting to valves

5.3.1 Mounting for valve-lift up to 30 mm (yoke version)
turn
Hexagon nut Hexagon nut

Valve spindle Valve spindle
Fig. 7
To mount the thrust actuator to a valve having a nominal lift of up to 30mm, proceed
as follows:
- Screw coupling (pos. 50.27) out of torsion safety feature (pos. 50.32) of thrust
actuator (not illustrated).
- Position valve cone approximately in mid lift position.
Fig. A: - Turn flat hexagon nut if not present on valve spindle.
Fig. A-B: - Slip coupling (pos. 50.27) over valve spindle.
- Screw threaded bush (pos. 50.87) matching the valve onto the valve spindle in
accordance with setting dimension (Y) and lock with hexagon nut.
ATTENTION !
Setting dimension (Y) and fitting-projection (X) are measured with
inserted valve spindle. This means for
- 2-way valves at closed valve,
- 3-way valves with mixing plug at closed way B,
- 3-way valves with diverting plug at closed way A
After measuring put the valve plug back in the mid lift position!
- Setting dimension (Y) for fitting-projection (X) 60 and 83mm = 102mm.
Fig. C: - Place thrust actuator (pos. 50) on valve.
- Mount thrust actuator (pos. 50) on fitting with two T-head bolts (pos. 50.19), two
washers (pos. 50.20), two spring washers (pos. 50.21), two hexagon nuts
(pos. 50.22).
Fig. D/E: - Swing out handwheel lever (pos. 50.12.1) and use it to move out the thrust
actuator until the driving spindle (pos. 50.30) comes to rest on the threaded
bush (pos. 50.87).
Page 16 0040501000 2607

Fig. F: - Screw the coupling (pos. 50.27) firmly into the torsion safety feature
(pos. 50.32) and secure in place using grub screw M6 (pos. 50.35).
- Run valve to lowest position.
- Clip lift dial (pos. 50.23) onto yoke in such a way that top edge of torsion safety
feature is in alignment with tip of arrow mark on lift dial.
- Run valve to both final positions and check to ensure that these are safely
reached
- Carry out electrical connection (see point 5.4).
- Set travel switch S3 (see point 5.5.3.2).
0040501000 2607 Page 17

5.3.2 Mounting for valve lift over 30 mm to 80 mm (column version)
turn
Hexagon nut Hexagon nut

Valve spindle
Valve spindle
Fig. 8
To mount the thrust actuator to a valve having a nominal lift of over 30mm to 50mm,
proceed as follows:
- Screw coupling (pos. 50.27) out of torsion safety feature (pos. 50.32) of thrust
actuator
(not illustrated).
- Position valve cone approximately in mid lift position.
Fig. A: - Turn flat hexagon nut if not present on valve spindle.
Fig. A-B: - Slip coupling (pos. 50.27) over valve spindle.
- Screw threaded bush (pos. 50.87) matching the valve onto the valve spindle in
accordance with setting dimension (Y) and lock with hexagon nut.
ATTENTION !
Setting dimension (Y) and fitting-projection (X) are measured with
inserted valve spindle. This means for
- 2-way valves at closed valve,
- 3-way valves with mixing plug at closed way B,
- 3-way valves with diverting plug at closed way A
After measuring put the valve plug back in the mid lift position!
- Setting dimension (Y) for fitting-projection (X) 83mm = 102mm.
- Setting dimension (Y) for fitting-projection (X) 98mm = 116mm.
Page 18 0040501000 2607

Fig. C: - Slip 2-ear clamp (pos. 50.26) onto a distance column (pos. 50.24) press on
very lightly.
- Screw distance column with 2-ear clamps on opposite side of handwheel into
the flange in such a way that one of the 2-ear clamps is situated above the
torsion safety feature (pos. 50.32) and the other below.
- Screw the other distance column into the flange likewise.
- Place thrust actuator (pos. 50) with distance columns onto valve and fix into
position with two self-locking hexagon nuts (pos. 50.25).
Fig. D/E: - Fold out turning handle of handwheel (pos. 50.12.1), slightly turn the
handwheel and press in the engaging button for manual mode (only 12 - 15 kN)
(button engages). Having done this, move out the thrust actuator until driving
spindle (pos. 50.30) comes into contact with threaded bush (pos. 50.87).
Fig. F: - Screw coupling (pos. 50.27) firmly into torsion safety feature (pos. 50.32) and
secure using grub screw M6 (pos. 50.35).
- Move the valve to the lowest position.
- Press 2-ear clamps (pos. 50.26) into position according to the stroke so they
cannot slip, with the bottom clamp in the lowest valve position located directly
below torsion safety feature (pos. 50.32) and the top clamp in the highest valve
position located directly above the torsion safety feature.
- Move the valve to both travel positions and check that it reaches them reliably.
- Fold turning handle of handwheel (pos. 50.12.1) back in.
- Make the electrical connection (see point “5.4 Electrical connection”). The
engaging button for manual mode (only 12 - 15 kN) disengages when the
motor starts up.
- Set standard travel switch S3 (see point 5.5.3.2).
0040501000 2607 Page 19

standard accessories
Fig. 9
Page 20
Tele- Thermo- Current Voltage
Input resistance thermometer
transmitter element 0(4)...20mA 0(2)...10V
Binary input Binary output Logic 12V

alternativ to
binary inputs
bin1 and bin2
power
supply
230V/3A Binary output (Out1)
230V/3A Binary outpu t (Out2)

5.4.1 Wiring diagram ARI-PREMIO 2.2 - 5 kN
Output to the actuator

Voltage and power
0040501000 2607
supply voltage are equal
Wire connections of the different valve types HZ Heating resistor

3-way valve 3-way valve
Straight through valve with mixing plug with diverting plug DE Torque switch
A-AB open AB-B open

WE Travel switch for traveling the stroke distance
closed
(S3) in retracting direction
open B-AB open AB-A open
RI 21 Electronic position indicator
Option NA: ES 11 Electronic position controller

same design but no RC circuit NA Low-voltage connection board, zero potential
and switches with gold contacts
Standard-voltage connection board,
(Switching capacity 0.1A, 4-30VDC) PA zero potential
POT Potentiometer
WE Travel switch, zero potential
TTR Electronic temperature-controller dTRON 316
Standard Accessories
Fig. 10
Tele- Thermo- Current Voltage
Input resistance thermometer
transmitter element 0(4)...20mA 0(2)...10V
Binary input Binary output Logic 12V

alternativ to
binary inputs
bin1 and bin2
power
supply
230V/3A Binary output (Out1)
230V/3A Binary outpu t (Out2)
Option NA
same design as Standard but no RC
circuit and switches with gold contacts
(Switching capacity 0.1A, 4-30V) Output to the actuator
Wire connections of the different valve types Voltage and power
3-way valve 3-way valve supply voltage are equal
Straight through valve with mixing plug with diverting plug
5.4.2 Wiring diagram ARI-PREMIO 12 - 15 kN
Standard
closed A-AB open AB-B open
0040501000 2607
open B-AB open AB-A open HZ Heating resistor
DE Torque switch
WE Travel switch for traveling the travel
(S3) distance in retracting direction
RI 21 Electronic position indicator
External reversing contactor: ES 11 Electronic position controller
L1, L2, L3 - actuator spindle drives in
L3, L2, L1 - actuator spindle drives out Low-voltage connection board,
NA
In all external reversing circuits the torque zero potential
switches S1 and S2 have to be used to POT Potentiometer
switch off the actuator motor.
WE Travel switch, zero potential
5.4.2.1 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ without reversing contactor
external TTR Temperature-controller dTRON 316

reversing Please check the operating direction
contactor of the actuator ! WS Reversing contactor
PR Phase control relay
TR Temperature switch motor
Page 21
Accessories WS + PR
Fig. 11
Page 22
Wire connections of the different valve types
3-way valve 3-way valve
Straight through valve with mixing plug with diverting plug
3-step input signal Connect 3 phases L1, L2, L3 only here
closed A-AB open AB-B open
Accessories WS
open B-AB open AB-A open
0040501000 2607
5.4.2.2 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ with reversing contactor
3-step input signal Connect 3 phases L1, L2, L3 only here
Please check the operating direction

of the actuator !
5.4.3 Connection
ATTENTION !
- Work on electrical systems or equipment must only be carried out by qualified
electricians or by trained individuals under the guidance and supervision of a
qualified electrician in compliance with regional electrical requirement and
regulations.
- When connecting the thrust actuator the supply line must be disconnected from
the mains (not live) during connection work. It must be impossible to switch the
power on unintentionally while the mains are disconnected in this way. Failure
to comply may result in death, serious injury or substantial damage to property.
To connect the thrust actuator up to the electrical power supply, proceed as follows:
- Run the thrust actuator a few mm out of the lower final position applying the manual mode.
- Loosen countersunk screw in hood, carefully remove hood in upward direction.
- Remove blind plug fom the cable connection.
- Insert the connection line through this cable inlet until sufficient conductor length is
available up to the corresponding terminals; then tighten the cable connection until the
connecting cable is clamped in place inside it.
- Strip connecting cable approx. 1-1.5 cm above cable inlet.
- Strip the individual conductors approx. 5mm away from the end and fit with conductor end
sleeves.
- Connect protective conductor of connecting cable up to protective conductor terminal of
thrust actuator.
- Connect neutral N/MP conductor of connecting cable up to terminal 1/N of thrust-actuator
terminal strip.
- Connect pulse line for move-out connecting rod up to terminal 11 of thrust-actuator
terminal strip.
- Connect pulse line for move-in connecting rod up to terminal 14 of thrust-actuator terminal
strip.
- Place hood on carefully from above and mount firmly onto thrust actuator with
countersunk screw and rubber gasket.
- Connect supply line to mains and run thrust actuator to each of the final positions so as to
check whether the final-position travel switches effect switching off, also checking to see
whether the direction of movement on the thrust actuator corresponds to the desired
direction.
- If the directions of movement are contrary to those desired, the pulse lines governing the
move-in and move-out connecting rod will need to be exchanged.
0040501000 2607 Page 23

5.5 Settings
ATTENTION !
- The thrust actuator may only be operated for a short time without the hood for
unavoidable setting operations to the potentiometers, travel switches and the
electrical options. While these operations are in progress, the thrust actuator
has hazardous, live, uninsulated parts exposed as well as moving and rotating
parts.
- Improper execution of the setting operations or lack of care may cause death,
grievous bodily injury or substantial property damage.
- Operation of the thrust actuator without the hood for any purpose other than
that described above is strictly prohibited.
5.5.1 Torque and travel switches

The thrust actuators are equipped with a load-dependent travel switch for the extending
direction (S1), a load-dependent travel switch for the retracting direction (S2) and a stroke-
dependent travel switch for the retracting direction (S3).
The load-dependent travel switches (S1, S2) switch off the motor as soon as the factory-set
thrust force is attained.
ATTENTION !
- The settings of the load-dependent travel switches must on no account
whatsoever be changed!
- The function of the stroke-dependent travel switch (S3) is ensured only with the
optionally available trip slide
The stroke-dependent travel switch (S3) switches off the motor as soon as the lift or stroke
is attained. If the thrust actuator is supplied on a straight through valve, the stroke-
dependent travel switch S3 is set in such a way that the motor of the thrust actuator is
switched off as soon as the maximum valve-lift is attained.
If the thrust actuator is supplied on a three-way valve, the trip cam belonging to travel
switch S3 is set in the retracting direction in the trip slide to such a downward extent that the
upper final position of the valve is attained prior to travel switch S3 being reached, thus
causing the load-dependent travel switch S2 to switch off the motor.
For this function, all three switches reveal interlock-controlled circuitry on the board.
If the standard travel switches are to be integrated directly into the facility control system,
the standard board can be replaced by optional boards PA or NA (only 2.2-5kN).
5.5.2 Connection boards PA or NA (only 2.2 - 5 kN)

On connection boards PA or NA, the standard travel switches S11/S21, S12/S22 and S13/
S23 do not reveal interlock-controlled circuitry and can be integrated individually into the
facility control system.
The 3 contacts on each of the switches S11/S21, S12/S22 and S13/S23, designed as
double-throw contacts, are - in the case of these boards - brought out on terminals 40-48
and can be freely connected.
The switches on the PA optional board (standard-voltage connection board) are designed
for switching capacities of up to 10A, 250V AC.
The switches on the NA optional board (low-voltage connection board) are designed for
switching capacities of up to 0.1A, 4-30V (gold contacts).
Page 24 0040501000 2607

The optional boards may only be installed at the factory due to the switching points of the
load-dependent switches having to be reset following installation of these boards!
ATTENTION !
- When using optional boards PA or NA, it must be warranted - due to the
operator’s individual circuitry- that, when switching the load-dependent travel
switches S11/21, S12/S22 and S13/S23 the motor of the thrust actuator comes
to a standstill without delay.
This function is not provided for on the optional boards PA and NA in the
supplied state!
5.5.3 Travel switch

The thrust actuators can be equipped with an additional stroke-switch board containing two
travel switches (double-throw contact S4 and S5).
These switches can be set on infinitely variable lines over the entire stroke distance in both
lift directions and integrated at will into the facility control system (no interlock-controlled
circuitry).
The maximum switching capacity of the switches (see point “4.4 Technical data”) must not
be exceeded.
For low voltage (see point “4.4 Technical data”), the additional travel switches are supplied
with gold contacts (option: low-voltage travel switch).
5.5.3.1 Installation of additional travel switches
To install additional travel switches, proceed as follows.
- Switch off mains voltage and safeguard to prevent it from being switched back on again
accidentally.
- Loosen countersunk screw in hood, carefully remove hood.
- Disconnect motor plug and mains connection plug from board.
- Carefully ease open the lock washer (pos. 50.56) (open ends) with a screw driver while
pulling the trip slide (pos. 50.50) upwards from the board support.
- Remove trip slide (pos. 50.50) from board support by pulling upwards.
- Loosen head cap screws (pos. 50.57) on board support and remove this from gearbox
(only necessary on 5kN thrust actuator).
- Insert stroke-switch board (pos. 50.61) in board support (pos. 50.42) and fix in place using
the supplied screws (pos. 50.44).
- Mount board support loosely on gearbox cover plate with two head cap screws (pos.
50.57) (only necessary on 5kN).
- Push trip slide (pos. 50.50) back into board support (pos. 50.42) from above and onto the
guide spindle (pos. 50.38).
- Align board support (pos. 50.42) on gearbox cover plate in such a way that the guide
spindle (pos. 50.38) is centrally situated in the borehole of the trip slide (pos. 50.50); then
screw down tightly on gearbox cover plate (only necessary on 5kN).
- Mount the trip slide (pos. 50.50) so that the spring (pos. 50.56) clips into the groove of the
guide spindle (pos. 50.38).
- Insert 6-pole connector (pos. 50.62) in jack strip of stroke-switch board.
0040501000 2607 Page 25

- Proceed to strip the connecting cable that has been led in through the cable inlet and
fastened, and connect the individual conductors to the terminal strip in accordance with
the desired circuitry and the wiring diagram.
- Set switch points on travel switches in accordance with section 5.5.3.3 Setting the
additional travel switches (S4/S5 and S24/S25)
- Insert motor connection plug in jack strip (pos. 50.43.4) provided for the purpose.
- Insert mains connection plug in jack strip (pos. 50.43.3) provided for the purpose.
- Carefully place hood onto gearbox and mount firmly on thrust actuator with rubber gasket
and countersunk screw.
Fig. 12 Switchgear and indicating feature ARI-PREMIO 2.2 - 5 kN

50.38 Guide spindle 50.52 Setting spindle for switch S4
50.42 Board support 50.53 Setting spindle for switch S5
50.43.3 Jack strip for mains connection 50.54 Trip cam
50.43.4 Jack strip for motor connection 50.56 Spring
50.44 Self-tapping screw 50.57 Head cap screws DIN EN ISO 4762 -
M4x10
50.50 Trip slide (option) 50.61 Stroke-switch board
50.51 Setting spindle for switch S3 50.62 Connector, 6-pole
(option: travel switch)
Page 26 0040501000 2607

5.5.3.2 Installation and setting of the travel switch (S3)
To install guide spindle and trip slide for the travel switch, proceed as follows:
accidentally.
- Disconnect motor plug and mains connection plug from board.
- Screw the hexagon nut M5 (pos. 50.39) approx. 6mm on the guide spindle (pos. 50.38)
- Screw the guide spindle in accordance with setting dimension E=50mm into the drive
spindle (pos. 50.30) and counters with the hexagon nut M5.
- Lubricate trip slide (pos. 50.50) at the bearing surface ends with grease
- Push trip slide (pos. 50.50) into board support (pos. 50.42) from above and onto the guide
spindle (pos. 50.38).
- Mount the trip slide (pos. 50.50) so that the guide spindle (pos. 50.38) is centrally situated
in the borehole of the trip slide and the spring (pos. 50.56) clips into the groove of the
guide spindle.
- Insert motor connection plug in jack strip (pos. 50.43.4) provided for the purpose.
- Insert mains connection plug in jack strip (pos. 50.43.3) provided for the purpose.
- Carefully place hood onto gearbox and mount firmly on thrust actuator with rubber gasket
and countersunk screw..
Groove for spring
Fig. 13: Spindle and trip slide installation

50.30 Drive spindle 50.51 Setting spindle for switch S3
50.38 Guide spindle 50.52 Setting spindle for switch S4
50.39 Hexagon nut DIN EN ISO 4034 - M5 50.53 Setting spindle for switch S5
50.42 Board support 50.54 Trip cam
50.50 Trip slide 50.56 Spring PREMIO for trip slide
0040501000 2607 Page 27

Installing the thrust actuator on a straight through valve, the travel switch S3 needs
to be set as follows:
- Move valve out of the lowest position so as to run valve-lift to up position.
- Using a screw driver, proceed to turn setting spindle for switch S3 (pos. 50.51) until the trip
cam (pos. 50.54) arriving from below trips the switch (audible click).
- Run thrust actuator briefly in extending direction and then in retracting direction once
more, checking to see whether the thrust actuator is switched off at the desired point
(nominal lift).
- If need be, correct the setting as described.
Installing the thrust actuator on a three-way valve, the travel switch S3 needs to be
set as follows:
- Run valve in both final positions and check in each final position whether the valve
switches off via the load-dependent switch.
- Carry out a check in the top final position the see whether, after switching off the thrust
actuator, the trip cam (pos. 50.54) of the travel switch S3 is situated below switch S3 and
has not tripped the latter. If the trip cam (pos. 50.54) is situated above the travel switch S3
or trips the same, the setting spindle governing the travel switch S3 (pos. 50.51) needs to
be turned until the trip cam is situated below travel switch S3 without tripping it.
- Run the thrust actuator in both final positions once more and check whether thrust
actuator switches off in both final positions via the load-dependent switches.
- If need be, correct the setting as described above.
5.5.3.3 Setting the additional travel switches (S4/S5 and S24/S25)

The two additional travel switches can be freely set in both lift directions for indicating
certain valve positions.
To do this, proceed as follows:
- Run valve to desired position due to be indicated by the corresponding switch.
- Proceed to turn the setting spindle belonging to the appurtenant switch until the switch is
tripped (audible click).
- Run thrust actuator briefly in both directions, checking and, if need be, correcting the
setting.
The actuating feature on the travel switches is designed in such a way that both travel
switches can be overrun in both directions.
Standard design:
For that reason, care should be taken on additional travel switches to see that the actuating
state of the switches remains active only for a short time while the thrust actuator continues
to run and that switching back takes place afterwards.
The actuating state of the travel switches remains in force over a lift of 4 mm.
Special design:
At additional travel switches with extended switch levers, the actuating state of the travel
switches remains in force over a lift of 49 mm.
Page 28 0040501000 2607

5.5.4 Potentiometers
The potentiometers are used for electrical position acknowledgement on the facility control
system or for the options - electronic position controller ES11 or electronic position indicator
RI21
A maximum of 2 potentiometers can be installed (= 1 double potentiometer).
The potentiometers can be supplied with different resistance values
(see point „4.4 Technical data“).
For the electronic position controller ES11 and the electronic position indicator RI21 use
must be made solely of 1000 ohm potentiometers.
Conversion of the relevant valve-lift to the potentiometer angle of rotation is effected by
means of transmission determined in respect of each valve-lift between the toothed rack on
the trip slide and the pinion on the potentiometer shaft.
Use must only be made of the pinion specified for the valve-lift.
If the thrust actuator is supplied with the valve and built-in potentiometer, the potentiometer
is assembled and set ready for operation.
To achieve optimal electromagnetic compatibility it is recommended to use shielded cables
for connecting potentiometers or standardized active current or voltage signals.
5.5.4.1 Installing the potentiometer
If retrofitting the potentiometer, proceed as follows:
accidentally.
- Plug in the flat connectors on grey potentiometer cables onto the middle connector pins,
those of the red cables onto the upper connector pins and those of the yellow cables onto
the lower connector pins of the potentiometer (Fig. 14 ).
- Insert the potentiometer into the guide in the way that the pinion (pos. 50.73) of the
potentiometer meshes with the gear stick of the trip slide.
- With a valve lift up to 30 mm, hook spiral spring (pos. 50.70) into the left-hand window of
board support (pos. 50.42) above the potentiometer guide, insert into the guide between
the slide block and the potentiometer guide and hook into the cut-out below the
potentiometer.
With a valve lift between 30 mm and 50mm, hook spiral spring (pos. 50.70) into the right-
hand window (for 12 - 15kN middle window) above the potentiometer guide, insert into the
guide between the slide block and the potentiometer guide and hook into the cut-out
below the potentiometer.
With a valve lift between 50 mm and 65 mm, hook spiral spring (pos. 50.70) into the
middle window in board support (pos. 50.42) above the potentiometer guide, insert into
the guide between the slide block and the potentiometer guide and hook into the cut-out
below the potentiometer.
- Check to see whether pinion (pos. 50.73) is pressed into toothed rack by spiral spring
(pos. 50.70) and is positioned free from backlash.
- If this is not the case, remove spiral spring (pos. 50.70), readjust by bending a little, and
place back in position again.
- Screw jack strip of connecting cable (pos. 50.68) to board support (pos. 50.42) with two
self-tapping screws (pos. 50.69) (single potentiometer connectors 25-27).
- Insert additional 3-pole connector (pos. 50.74) in jack strip of connecting cable
(pos. 50.68).
0040501000 2607 Page 29

- Set potentiometer (see point 5.5.4.2).
- Place hood carefully onto thrust actuator and fasten it on the actuator with rubber gasket
and countersunk screw.
red grey
red
grey
yellow
yellow
Fig. 14
Fig. 15: Switchgear and indicating feature ARI-PREMIO 2.2 - 5 kN

50.42 Board support 50.68 Connecting cable for option:
potentiometer
50.46 Washer 50.69 Self-tapping screw
50.47 Circuit-diagram sticker 50.70 Spiral spring (option:
potentiometer)
50.67.1 Hexagon nut 50.71 Slide block (option: potentiometer)
50.67.2 Tooth lock washer 50.73 Pinion (selection depends on
valve-lift 20, 30, 50, 65 or 80 mm)
50.67.3 Potentiometer 50.74 Connector, 3-pole
(option: potentiometer)
Page 30 0040501000 2607

5.5.4.2 Setting the potentiometer
To set the potentiometer, proceed as follows:
- Move thrust actuator to extended position.
accidentally.
- Turn potentiometer shaft in counter-clockwise direction until reaching the travel stop.
This places the potentiometer in the initial position (approx. 0 ohm).
- For checking purposes, the resistance of the potentiometer needs to be measured using
an ohmmeter.
- Measure resistance on potentiometer 1 between terminals 25 and 26.
- In this position of the actuator, the measured value should be approx. 0 ohm.
- Run thrust actuator to upper final position and read off corresponding resistance value on
ohmmeter.
- The resistance values thus measured need to be taken into account for the settings to the
0040501000 2607 Page 31

5.5.5 Error-proof potentiometer for single-channel, error-proof position feedback
The TÜV certified potentiometer on conductive plastic basis is used for single-channel,
error-proof position feedback in connection with error-proof, electronic group monitoring
systems for the regulation of fuel -, air and exhaust gas streams.
A maximum of 2 potentiometers can be installed (=1 double potentiometer).
The potentiometers can be supplied with different resistance values (see point „4.4
Technical data“).
For the electronic position controller ES11 use must be made solely with 1000 ohm
potentiometers
The conversion of the relevant valve-lift to the potentiometer angle of rotation is effected by
the transmission between the toothed rack on the trip slide and the pinion on the
potentiometer shaft.
The pinion and the potentiometer shaft are firmly connected.
If the thrust actuator is supplied with the valve and built-in potentiometer, the potentiometer
is assembled and set ready for operation.
The potentiometer is with the options „Heating“ and “position indicator RI21“ not
combinably.
To use for the electromagnetic compatibility, shielded lines are recommended for
potentiometers and electrical unit signals.
Don`t lay signal lines parallel to the main line!
ATTENTION !
- In order to achieve as high a life span as possible with maximum accuracy,
potentiometers on conductive plastic basis are not as adjustable pre-resistors
to begin but as read-free voltage dividers!
- An additional installation of the option „Error-proof potentiometer“ is not
permitted for safety reasons.
5.5.5.1 Setting the potentiometer on conductive plastic basis

To set the potentiometer, proceed as follows:
- Move thrust actuator to extended position.
accidentally.
- For checking purposes, the resistance of the potentiometer needs to be measured using
an ohmmeter.
- Loose the potentiometer by unscrewing the 2 screws and remove it incl. pinion from the
toothed rack.
- Turn potentiometer shaft (angle of rotation mech. 360°, electr. 320° without stop) and by
means of ohmmeter bring the potentiometer in initial position (approx. 0 Ohm).
- Bring the potentiomter and the pinion back in contact with the toothed rack and fasten the
screws.
- Subsequently, the screws are to be provided again with locking lacquer.
- Run thrust actuator to upper final position and read off corresponding resistance value on
ohmmeter.
Page 32 0040501000 2607

- The resistance values thus measured need to be taken into account for the settings to the
Fig. 16: Error-proof potentiometer ARI-PREMIO 2,2 - 5 kN

50.38 Guide spindle 50.81 Head cap screw
50.39 Hexagon nut 50.120 Lever
50.42 Board support 50.121 Metal sheet
50.50 Trip slide (option) 50.122 Tension spring
50.67 TÜV-approved potentiometer 50.123 Pan-head screw
50.71 Slide block (option: potentiometer) 50.124 Straight pin, slotted
50.73 Pinion (travel 50 mm) 50.125 Hexagon nut M4, self-locking
50.74 3-pole connector 50.126 Hexagon nut M5, self-locking nut
(option: potentiometer)
0040501000 2607 Page 33

5.5.6 Heating
A heating resistor should be fitted as a means of protection against the formation of
condensation water in cases involving widely varying ambient temperatures, high
atmospheric humidity (outdoor use) and temperatures below the freezing point. The heating
resistor is self-regulating so that a continuous supply of current merely needs to be
connected up.
5.5.6.1 Installation of heating
On principle, the heating can be combined with all options. It is completely mounted on a
holding bracket.
If electronic system ES11 or RI21 is already installed, unscrew the electronic system from
the holding bracket, remove it, install the heating and attach the electronic system to the
holding bracket for the heating.
To install the heating proceed as follows:
accidentally.
- Using the supplied screws, mount complete heating (on holding bracket) at the point on
the gearbox cover plate provided for the purpose. (Fig. 18).
- Lead continuous-current cable (mains voltage = rated voltage of heating) through cable
inlet into thrust actuator and fix in place with inlet.
- Strip continuous-current cable approx. 1-1,5 cm above cable inlet.
- Strip individual conductors approx. 5mm away from the end and provide with conductor
end sleeves.
- Lay the individual conductors in such a way that they do not come into contact with
moving parts.
- Connect the individual conductors up to the connection terminal block in accordance with
the wiring diagram.
Mounting thread M3 Mounting thread M3

for heating resistor for thermal circuit breaker
Mounting thread M4
for options ES11 and RI21
Mounting thread M3
for jack strip
Fig. 17: Heating installation ARI-PREMIO 2.2-15 kN

50.83.1 Holding bracket 50.83.4 Jack strip
(Option: heating)
50.83.2 Head cap screw DIN 84-M3x8 50.83.6 Connector, 2-pole
50.83.3 Thermal circuit breaker 50.83.10 Heating resistor
Page 34 0040501000 2607

5.5.7 Electronic position indicator RI21
The electronic position indicator RI21 converts the resistance of the 1000 ohm
potentiometer corresponding to the lift into an optional output control signal 0 (2) ...10V DC
or 0 (4) ...20mA DC. For installing and setting the electronic position indicator RI21 the
operating instructions applicable to this unit must be observed in the appropriate valid
version. The corresponding operating instructions are supplied with each unit.
5.5.8 Electronic position controller ES11

The electronic position controller ES11 converts continuous input control signals 0 (2)
...10V DC or 0 (4) ...20mA into a 3-point output signal for the motor, in which case
interrogation of the valve position takes place via a 1000 ohm potentiometer. For installing
and setting the electronic position controller ES11 the operating instructions applicable to
this unit must be observed in the appropriate valid version. The corresponding operating
instructions are supplied with each unit.
Fig. 18: Installing RI21 / ES11 / heating ARI-PREMIO 2.2 - 5 kN

50.78/79 Option ES11 or RI21 50.81 Head cap screw
50.80 Holding bracket 50.82 Head cap screw
0040501000 2607 Page 35

5.5.9 Electronic position indicator (RI21) and position controller (ES11) together in
the actuator
Except or the 5 kN, 12 kN and 15 kN type in 24V version, the electronic position indicator
RI21 and the electronic position controller ES11 can be build-in together in the ARI-
PREMIO.
It must be used a double potentiometer with 1000/1000 Ohm.
To install the RI21 and ES11 proceed as follows:
accidentally.
- Loosen counter-sunk screw in hood, carefully remove hood.
- Mount RI21 and ES11 with mounting kit according to Fig. 19.
Fig. 19: Installing RI21 / ES11 at the same time as ARI-PREMIO 2.2 – 5 kN

50.67 Potentiometer 50.82 Head cap screw
50.78/79 Option ES11 or RI21 50.106 Metal sheet ES11 and RI21
50.81 Head cap screw 50.108 Distance bold
Page 36 0040501000 2607

5.5.10 Integrated temperature controller dTRON 316
The integrated temperature controller controls temperatures, which are measured by input-
connected temperature sensors, to a manual given setpoint by means of a three-step
output connected with the actuator.
5.5.10.1 Installation of the dTRON 316

The dTRON 316 can be mounted in the ARI-PREMIO as a complete unit with a mounting
kit.
It cannot be combined with ES11.
To install the dTRON 316 proceed as follows:
In addition to “5.4.3 Connection”, the electrical connection of the dTRON 316 has to be
done in the following way:
- Mount the temperature controller on the gear plate by using the specific installation kit
(Fig. 20).
- Plug in the connector X2 of the dTRON 316 to the plug-in connector X1 (1/N, 11, 14) of the
actuator terminal.
- Connect the signal input and the individual wanted additional functions according the
wiring diagram to the dTRON 316.
- Connect the power supply L1 and N to the dTRON 316.
- For changing the working direction to heating signal = extending driving spindle, just
change the wires on the connectors 11 and 14.
Pos. Designation
50.81 Head cap screw
50.97 Temperature controller dTRON 316
50.98 Fixing bracket (option dTRON)
50.99 Holding bracket (option dTRON)
50.100 Self-locking nut (option dTRON)
Fig. 20: Installing dTRON 316 ARI-PREMIO 2.2 – 5 kN
0040501000 2607 Page 37

5.5.11 Integrated reversing contactor
The integrated reversing contactor is actuated using a 3-step input signal.
The reversing contactor swaps over phases L1, L2 and L3 to achieve the desired direction
of rotation of the three-phase motor.
5.5.11.1 Installing the reversing contactor

The reversing contactor can be mounted in the ARI-PREMIO as a complete unit using a
mounting kit.
The reversing contactor can only be combined with one of the ES11, RI21 or temperature
controller options. It is also possible to install the heating and the phase control relay.
Proceed as follows to install the reversing contactor:
Switch off the mains voltage and take measures to prevent it being switched back on
inadvertently.
ATTENTION !
- When the reversing contactor is installed without a phase control relay, the
thrust actuator may be damaged if phases L1, L2 and L3 are wrongly
connected!
The electrical connection procedure as described in 6.4.3 Connection is supplemented by

the following steps:
- Use the mounting kit to attach the reversing contactor to the gear plate (fig. 19).
- Connect the three-phase connection L1, L2, L3 and the 3-step input signal as shown in
fig. 11.
- Wire up as shown in the table in fig. 10 if you are connecting the reversing contactor
without a phase control relay.
- Refer to “5.5.12 Phase control relay” regarding connecting with a phase control relay.
5.5.11.2 Electrical connection with ES11 or dTRON 316

Modify the 3P output cable of the ES11 or the dTRON 316 as follows:
- Remove plug X25.
- Strip off the outer cable insulation down to about 18 cm.
- Connect the individual conductors as follows:
Black (L↑) - S2/14
Brown (L↓) - S1/11
Blue (1/N) - K1/A2, K2/A2
Page 38 0040501000 2607

5.5.12 Phase control relay
The phase control relay monitors phases L1, L2 and L3 in the mains input supply. The
reversing contactor is only activated by the phase control relay providing phases L1, L2 and
L3 are connected correctly. This protects the thrust actuator.
5.5.12.1 Installing the phase control relay

The phase control relay is installed in the ARI-PREMIO next to the reversing contactor. It is
only possible to use the phase control relay in conjunction with the reversing contactor. It
cannot be combined with the dTRON 316 temperature controller in the actuator.
Proceed as follows to install the phase control relay:
Switch off the mains voltage and take measures to prevent it being switched back on
inadvertently.
The electrical connection procedure as described in „5.4.3 Connection“ and „5.5.11
Integrated reversing contactor“ is supplemented by the following steps:
- Attach the phase control relay next to the reversing contactor (Fig. 20).
- Connect the three-phase connection L1, L2, L3 and the 3-step input signal as shown in
Fig. 10.
Pos. Designation
50.57 Head cap screw
DIN EN ISO 4762 - M4 x 10
50.59 Head cap screw DIN EN ISO 4762 - M4 x 6
50.81 Head cap screw DIN EN ISO 4762 - M4 x 8
50.102 Reversing contactor
50.103 Fixing plate (option reversing contactor)
50.105 Phase control relay
50.107 Bracket (option phase control relay)
Fig. 21: Installing reversing contactor and phase control relay ARI-PREMIO 12 – 15 kN
0040501000 2607 Page 39

5.5.13 DC-MODULE
Three-step converter for control of electric thrust actuator ARI-PREMIO 230V 50Hz 2.2 to 5
kN, with 24V DC voltage.
The DC MODULE converts a 24V input DC voltage into a 230V 50Hz 3-step output signal
depending on polarity.
Characteristics
- 3-step converter, for conversion of a 24V input DC voltage into a 230V 50Hz 3-step output
control signal, for OPEN – STOP – SHUT functions
- Fitted to the ARI-PREMIO, or wall-mounted
- Simple 2-wire control
- Direction of rotation changed simply by reversing polarity
- Electronics installed in a strong protective housing
- Position controller ES11 and position indicators RI21 and RI32 can be used as optional
extras
- Can be retrofitted to the ARI-PREMIO 2.2 – 5kN 230V 50Hz thrust actuator
5.5.13.1 Fitting the DC MODULE to ARI-PREMIO

The DC MODULE is mounted to the outside of the ARI-PREMIO.
- Release screws (pos. 50.120.6) and remove cover (pos. 50.120.5) from body
(pos. 50.120.4).
- Fasten body (pos. 50.120.4) to retaining plate (pos. 50.120.1) with screws (pos. 50.120.3).
- Unscrew 2 x hexagon bolts (pos. 50.120.2) with lock washers (pos. 50.16) on connection
side of ARI-PREMIO.
- Fasten retaining plate (pos. 50.120.1) with the 2 x hexagon bolts (pos. 50.120.2) and
secure lock washers (pos. 50.16).
- Connect DC MODULE in accordance with wiring diagram.
- The cable from the DC module must be taken through the cable glands on the drive and
screwed.
- Once connection is complete, screw the cover (pos. 50.120.5) back on to the body (pos.
50.120.4).
ATTENTION !
- High voltages are induced in the DC MODULE and ARI-PREMIO.
- Even with only 24V in the input, voltages can reach over 230V.
- For a safe connection it is vital to isolate the 24V in the input.
(Isolation means that the voltage to a system is switched off at all poles)
Page 40 0040501000 2607

Fig. 22: DC Module Option ARI-PREMIO 2,2 - 5 kN

50.16 Lock washers 50.120.3 Head cap screw M4 x 12
50.120 DC module complete 50.120.4 Body
50.120.1 Retaining plate 50.120.5 Cover
50.120.2 Hexagon bolt M10 x 45 50.120.6 Head cap screw M4 x 20/7
0040501000 2607 Page 41

5.5.13.2 Technical data - DC-Module
Type DC-Module
Supply voltage V 24V DC voltage, +10%/-20% (smoothed)
Current consumption A 1 - 5 A (5 A at full load), approx. 0.5 A at no-load
Operating mode EN 60034-1/ S1 – 100% ED
A11
Output voltage V 230V (at no-load above 230V AC)
Output frequency Hz 50Hz
Power output VA 65VA
Protection type EN 60529 IP 65
max. ambient temperature °C -20°C...+70°C
Weight kg 2
Dimensions DC MODULE mm BxHxT 160x100x83
(without retaining plate and screw fittings)
Connection / installation DC-Module

Electrical connection using screw terminals max 2,5mm2
Ensure suitable conductor cross-section, as a high voltage drop
occurs in long conductors!
Add-on to thrust drive ARI- PREMIO 230V 50Hz 2,2 - 5kN (max. 65VA)
PREMIO
ARI-PREMIO with with ES11 230V (option)
Position controller ES11
ARI-PREMIO with mit RI21 230V (option)
Position indicator RI21 only possible in conjunction with ES11 (option)
ARI-PREMIO with mit RI32 (option)
Position indicator RI32 only possible as two-wire connection in current loop
Not possible in combination with dTRON temperature regulator
Page 42 0040501000 2607

Fig. 23
ARI-PREMIO 2,2-5kN, with DC-MODULE Accessorie
or Potentiometer connection optionally

with R1 or R2 potentiometers
from 100 Ohm to 20 kOhm
0040501000 2607
Two-wire connection
Polarity for extending (current loop)
PREMIO stem 4...20mA
24V DC
Polarity for retracting
PREMIO stem
Four-wire connection
4...20mA
24V DC and AC
Input
5.5.13.3 Wiring diagram ARI-PREMIO 2.2 - 5 kN + 3-step DC module
2...10V
24V DC and AC
Page 43
Fig. 24
Page 44
ARI-PREMIO 2,2-5kN, with DC-MODULE Accessorie
0040501000 2607
Polarity for extending
PREMIO stem
from DC- or from DC- or
5.5.13.4 Wiring diagram ARI-PREMIO 2.2 - 5 kN + DC module
MODULE MODULE
Polarity for retracting
PREMIO stem
to RI21
to ES11
5.5.14 Electronic position indicator RI32
The RI32 electronic indicator transforms a resistance change into a 4...20mA or 2...10V
standardised control signal.
The RI32 position indicator can be operated by 24V DC voltage or 24V AC voltage.
It is possible to link into a current loop without an additional power supply.
5.5.14.1 Useful range of the linear motion

potentiometer
Linear motion potentiometers R1 or R2 are
connected in a three-conductor connection.
Here the RI32 position indicator is also suitable
for conductive plastic potentiometers.
adjustable
The diagram on the right will help when zero point setting range
adjusting the RI32 position indicator to the
stroke distance of the linear motion
potentiometer.
It is important that the mechanical stroke
distance of the control actuator is smaller than adjustable
slope span setting range
the stroke distance of the linear motion
potentiometer.
Fig. 25: Linear motion potentiometer
5.5.14.2 Installing the RI32 electronic position indicator in the PREMIO

- The RI32 position indicator is fitted to the ARI-PREMIO as illustrated.
- Screw fixing bracket (pos. 50.98) to gearbox cover plate with head cap screw (pos. 50.81).
- Then fit position indicator (pos. 50.121) to fixing bracket (pos. 50.98) with the head cap
screws (pos. 50.59) and washers (pos. 50.122).
Fig. 26: Option RI32 ARI-PREMIO 2,2 - 5 kN

50.59 Head cap screw M4 x 6 50.98 Fixing bracket
50.67 Potentiometer 50.121 Position indicator RI32
50.81 Head cap screw 50.122 Washer 4.3
0040501000 2607 Page 45

5.5.14.3 Electronic position indicator (RI32) and position controller (ES11)
together in the actuator
The electronic position indicator RI32 and the electronic position controller ES11 can be
build-in together in the ARI-PREMIO.
It must be used a double potentiometer with 1000/1000 Ohm.
To install the RI32 and ES11 proceed as follows:
accidentally.
- Mount RI32 and ES11 with mounting kit according to Fig. 27.
Fig. 27: Installing RI32 / ES11 at the same time as ARI-PREMIO 2.2 – 5 kN

50.67 Potentiometer 50.82 Head cap screw
50.78 Option ES11 or RI21 50.121 Option RI32
Page 46 0040501000 2607

5.5.14.4 Technical data - Position indicator RI32
Type RI 32 Position indicator
Supply voltage V 24V DC / AC 50...60Hz
Potentiometer input Ω 1 kOhm ... 10 kOhm three-conductor connection, suitable for
conductive plastic potentiometer
Control signal output, V 2...10 V DC with (control signal output with supply voltage
voltage internal electrical connection)
Control signal output, mA 4...20 mA DC (load max. 500 W)
current (control output signal with supply voltage internal electrical
connection)
Measuring current at μA max. 800 μA
potentiometer arm
Linearity error % ± 0,2 % measurement range
Temperature coefficient %/K 0,04 %/K
Auxiliary energy inflow %/V 0,02 %/V
Protection type EN 60529 IP40 (terminals IP20)
Max. ambient temperature °C -40 °C...+85 °C
Humidity % 95 % r.F., no dewing
Weight g ca. 35 g
Dimensions mm Ø x depth 44 x 38
Connection / installation RI 32 Position indicator

Electrical connection using screw terminals max 2,5 mm2
Built into thrust actuator in ARI-PREMIO all versions
5.5.14.5 Potentiometer installation
ATTENTION !
When installing the potentiometer please note point „5.5.4 Potentiometer“ in
these Operating Instructions.
Plug Ra, Rb, Rc connector from potentiometer cable of RI32 position indicator into
pin strip 25, 26, 27 or 28, 29, 30 of the ARI-PREMIO.
0040501000 2607 Page 47

5.5.14.6 Wiring diagram
Control signal selection

The required control signal is adju-
sted using microswitches SA and
SB
or Potentiometer connection optionally

with R1 or R2 potentiometers
from 100 Ohm to 20 kOhm
Two-wire connection
(current loop)
4...20mA
24V DC
4...20mA
24V DC and AC
2...10V
24V DC and AC
Fig. 28
5.5.14.7 Connection conditions

The electrical connections are joined to position indicator RI32 by series disconnect
terminals. The connection to the potentiometer is made by a cable.
Position indicator RI32 is connected by a potentiometer (R1 or R2) built into the ARI-
PREMIO.
When the valve is shut approx. 0 ohm are applied between Rb and Rc.
Appropriate conductor cross-sections for terminal connections are 0.2 to 2.5 mm2.
To achieve electromagnetic compatibility is recommended that shielded conductors be
used for longer routings.
Please request technical information direct from ARI-Armaturen.
Page 48 0040501000 2607

5.5.14.8 Setting zero point and slope span
The 4...20mA or 2...10V output control signal is adjusted to the potentiometer stroke by
miniature potentiometers S (slope) and N (zero).
Zero point setting

- The zero point setting is always made before the slope span setting.
- Potentiometer must be at approximately 0 Ω.
- Before measuring resistance, isolate the potentiometer from the RI32 position indicator
and reconnect after measuring.
- Resistance measurement at the potentiometer cable between Rb and Rc.
- Make the connection in accordance with the wiring diagram.
- Zero point setting is made at the zero point setscrew marked N.
- Adjust zero point setscrew N so that the desired minimum control signal value is applied to
the meter.
- Rotate zero point setscrew N to the right to increase the output signal, rotate to the left
to reduce it (a slip clutch engages after 12 rotations)
For example:
- Current output ........minimum value ......... = 4 mA
- Voltage output ........minimum value ......... = 2 V
Slope span setting

The slope span setting is made after the zero point setting.
- Before measuring resistance, isolate the potentiometer from the RI32 position indicator
and reconnect after measuring.
- Resistance measurement at potentiometer cable between Rb and Rc.
- Adjustment of resistance range to control signal output range is set at the slope span
setscrew marked S.
- The meter from the zero point setting stays in the same measurement range for the slope
span setting.
- Adjust the slope span setscrew S so that the desired maximum control signal value is
applied to the meter.
- Rotate slope span setscrew S to the right to increase the output signal, rotate to the left
to reduce it (a slip clutch engages after 12 rotations).
For example:
- Current output ........maximum value ........= 20 mA
- Voltage output ........maximum value ........= 10 V
0040501000 2607 Page 49

6.0 Putting the actuator into operation

ATTENTION !
- Actuator components which rotate or move during operation are coloured red.
Crushing or injury hazard!
- all works has been completed!
- Regional safety instructions must be observed as a matter of policy.
- hood of thrust actuator assembled.
When placing into service proceed as follows:
- Using the handwheel, run the thrust actuator to approximately mid lift position.
- Apply brief pulses to the thrust actuator for each direction of movement and check
whether the directions of movement correspond to those desired. If this is not the case,
the pulse lines governing the retracting and extending action must be exchanged on the
thrust actuator.
- Run thrust actuator to the final position in each direction of movement and check whether
it switches off automatically and whether all externally moving parts are able to move
freely.
- If failing to function properly, check all installation and setting work previously carried out,
correcting if necessary, and afterwards place into service once again.
The thrust actuator requires very little maintenance. Accordingly maintenance in specified
intervals is not necessary.
Depending on the conditions governing use, the maintenance and maintenance-intervals
have to be defined by the operator.
The thrust actuator must not be cleaned with high-pressure equipment or aggressive
solvents or detergents injurious to health or highly inflammable.
During and after cleaning, an inspection should be carried out of the sealing points on the
thrust actuator.
If there is any sign of lubricant escaping or dirt having accumulated, the sealing elements
must be repaired.
8.0 Troubleshooting
Instructions.
ATTENTION !
- It is essential that the safety regulations are observed when identifying faults.
-

“9.0 Troubleshooting table”, the supplier or manufacturer should be consulted.
Page 50 0040501000 2607


ATTENTION !
Fault Possible Causes Remedy

Thrust actuator fails to move Power failure Ascertain and eliminate cause
Fuse has blown Replace fuse
Thrust actuator not properly Rectify connection on thrust
connected actuator in accordance with wiring
diagram
Short circuit due to: Ascertain exact cause,
- moisture - Dry the thrust actuator and
eliminate leakage
- wrong connection - Rectify connection on thrust
actuator in accordance with
wiring diagram
- motor has burned out - Check whether the mains voltage
agrees with the voltage specified
on the rating plate. Have motor
changed.
Connector contacts not plugged in/ Insert connector firmly in jack strip
not properly plugged into jack strip thus affected
(Only for 12 - 15 kN) Unscrew the motor mounting
Handwheel is still engaged and screw closest to the cable feed-
does not disengage when the through. (Manual release of the
motor starts up handwheel disengagement
mechanism.)
Thrust actuator alternates Motor operating capacitor Have motor operating capacitor
between clockwise and defective replaced
counter-clockwise rotation
Thrust actuator fails to run to Load-dependent travel switches Remove thrust actuator and send
final positions and also out of to factory for repair
produces chatter
/ defective
Voltage drop due to excessively Lay connecting cables in
long connecting cables or accordance with requisite output
inadequate conductor cross-
section
Mains fluctuations beyond Arrange for "clean" mains system
permissible tolerance travels within requisite tolerances
System pressure too high Reduce system pressure
Periodic failure on thrust Loose connection on feedline Tighten connections on terminal
actuator strips
Thrust actuator is switched off Travel switch S3 not set Set travel switch S3 in accordance
in retracting direction prior to corresponding to use with operating instructions
load-dependent switch (three-
way valve)
0040501000 2607 Page 51

10.0 Dismantlement of thrust actuator

ATTENTION !
- The supply line for connecting up the thrust actuator must be in the dead state
i.e. disconnected while dismantlement work is being carried out. After being
disconnected, the mains power must be prevented from being switched back
on again accidentally.
- The system must be run down (depressurised state) as the valve cone is not
held without the thrust actuator and would thus be conducted by the system
pressure.
- Valve plug approximately in mid lift position - on no account supported inside a
seat!
To dismantle the thrust actuator proceed as follows:
- Disconnect all cables led into thrust actuator from outside and remove from thrust
actuator.
- Place hood on carefully from above and fix in place with counter-sunk screw and rubber
gasket.
- Loosen grub screw inside torsion safety feature; screw coupling out of torsion safety
feature.
- Loosen clamping bolts connecting the thrust actuator to the fitting.
- Remove thrust actuator from valve.
appointed by us.

Page 52 0040501000 2607


as defined by
Directive about electromagnetic compatibility 2004/108/EEC and the
EG-Low voltage directive 2006/95/EEC
Declaration of the manufacturer

as defined by
the Machinery Directive 98/37/EC

Mergelheide 56-60, 33756 Schloß Holte-Stukenbrock
that the supplied model of

electric thrust actuator ARI-PREMIO
in the delivered version complies with the following regulations:
- Directive about electromagnetic compatibility 2004/108/EEC

Applied harmonized standards:
DIN EN 61000-6-1/3; DIN EN 61000-6-2/4
- EG-Low voltage directive 2006/95/EEC
EN 60204-1; EN 60335-1; EN 60730-1; DIN EN 60730-2-14
- EG-Machinery Directive 98/37/EC
EN 349; EN 60204-1; DIN EN ISO 12100-1; DIN EN ISO 12100-2
The supplied model is intended to be incorporated into machinery or assembled with other
machinery to constitute machinery covered by this directive and must be put into service
until the machinery into which it is be incorporated has been declared in conformity with the
provisions of the directive as amended by 98/37/EC.
........................................................
0040501000 2607 Page 53

Safety valves SAFE
SAFE SAFE-P
(Series 900) (Series 920)
SAFE-TC SAFE-TCP/TCS
(Series 940) (Series 960/950)
Contents
1.0 General information on operating 7.1 Setting instructions ................................................11
instructions ..................................................... 2 7.1.1 Removing the cap ........................................11
2.0 Notes on possible dangers........................... 2 7.1.2 Changing the set pressure
2.1 Significance of symbols ..........................................2 “without” spring change .............................. 12
7.1.3 Changing the set pressure
2.2 Explanatory notes on safety information .................2
“with” spring change ................................... 12
3.0 Storage and transport .................................. 3 7.2 Representation .................................................... 14
4.0 Description..................................................... 3
8.0 Troubleshooting .......................................... 15
4.1 Scope of applications ..............................................3
9.0 Troubleshooting table ............................... 15
4.2 Operating principles ................................................3
10.0 Dismantling the valve or the top part ..... 17
4.3 Diagram...................................................................4
4.3.1 Parts list ..........................................................5
11.0 Warranty / Guarantee ................................ 17
4.4 Technical data - remarks .........................................6
12.0 EC declaration of conformity ................... 18
4.5 Marking .................................................................7
5.0 Installation...................................................... 8
5.1 General notes on installation...................................8
6.0 Putting the valve into operation................. 10
7.0 Care and maintenance ................................ 11
Rev. 0040401000 1210 englisch

SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS

and repair.
ATTENTION !
Non-compliance with operating instructions is dangerous!

Read the operating instructions before installation, operation,
maintenance or disassembly and adhere to them strictly.

to property.
Page 2 Rev. 0040401000 1210


ATTENTION !
- At -20°C to +65°C.
4.0 Description
Safety valves are used to protect pressurised systems.
ATTENTION !
state the higher requirements when ordering
to TRD 110.
- When media in Fluid Group 1 are used, seal exteriors must be designed so that
they pose no danger to humans or the environment.
- Open safety valves (open bonnet / open cap) are not permissible for fluids,
dusty atmospheres, open air use or for any Group 1 fluids in accordance with
Pressure Equipment Directive 97/23/EC.
Safety valves are safety devices designed to prevent the pressure in any pressurised
system from exceeding the maximum permissible pressure by more than the permissible
tolerance of, usually +10%.
Rev. 0040401000 1210 Page 3

4.3 Diagram
Fig. 901 Fig. 941 Fig. 961
fig. 1
Fig. 902 / 912 / 903 / 904 / 922 / 924 / 945 / 946
WEDI Bellow
Lever Disc series 950 Bellow series 940

Fig. 951/952; 961/962
fig. 2
Page 4 Rev. 0040401000 1210

4.3.1 Parts list
Pos. Description Pos. Description

1 Body 32 Hex. nut
2 Seat (not changeable) 33 Lift bolt
2 Screwed seat (SAFE-TC) 34 Screw
3 Stud 35 Lift fork
4 Spindle guide 36 Lifting lever
7 Gasket 37 Spring
8 Hex. nut 38 Screw
9 Lift limitation ring 39 Bolt
10 Spindle ring 40 Split pin
11 Bonnet, closed 41 Lever open
12 Disc unit 42 Bonnet, open
13 Lifting aid 43 Bellow
14 Spindle 44 Ring
15 Gasket 45 Ring
16 Spring type straight pin 47 Ball
17 Adjusting screw 48 Retaining ring
18 Ball 55 Bellow unit
19 Spindle cap 59 Protective rim
20 Parallel pin 60 Spacer
21 Lock nut 61 Coupling
22 Hex. head screw 62 Weight
23 Lead seal 63 Guide bush
25 Snap ring 65 Coupling
26 Spring plate 66 O-Ring
27 Gasket 67 Lift button
28 Cap, closed 68 Spring type straight pin
29 Cap open 70 Balanced piston
31 Ring
Refer to the data sheet for information about materials.
Rev. 0040401000 1210 Page 5

4.4 Technical data - remarks
for
- Pressure-temperature-ratings, etc. refer to datasheet.
Series 900: DN 20/32 - DN 150/250, 1”x2“ - 6”x10”

EN-JL1040, EN-JS1049, 1.0619+N, 1.4408, SA 216 WCB
PN 16/16, PN 40/16, ANSI 150/150, ANSI 300/150
Approval acc. to:
Figure 901, 902, 911, - DIN EN ISO 4126-1, VdTÜV leaflet 100, AD2000-A2 and
912 TRD 421.
Application letter D/G and F
- ASME Code Section VIII-Division 1 (UV-Stamp)
Figure 903, 904, 990 -VdTÜV leaflet 100, -100/4, TRD 721, DIN EN 12828.
Application letter D/G/H and D (for Figure 904, 990)
Series 920: DN 20 - DN 100

EN-JL1040, 1.0619+N, 1.4408
PN 16, PN 40
Approval acc. to:
Figure 921-924 - DIN EN ISO 4126-1, VdTÜV leaflet 100, AD2000-A2 and
TRD 421.
Series 940: DN 15 - DN 25 (G 1/2“ - G 1“)

EN-JS1049, 1.4408
PN 40
Approval acc. to:
Figure 941-943 - DIN EN ISO 4126-1, VdTÜV leaflet 100, AD2000-A2 and
TRD 421.
Figure 945-946 -VdTÜV leaflet 100, -100/4, TRD 721, DIN EN 12828.
Application letter D/G/H and D
Series 950/960: DN 15 - DN 25 (G 1/2“ - G 1“)

EN-JS1049, 1.4581
PN 100
Approval acc. to:
Figure 951-953 - DIN EN ISO 4126-1, VdTÜV leaflet 100, AD2000-A2.
Figure 961-963 Application letter D/G and F
Accessories: Stainless steel bellow for back-pressure compensation;

elastomer bellow; soft sealing disc; lock bush; proximity switch;
heating jacket; test gag; rupture disc; support tongues;
removable lifting aid
Page 6 Rev. 0040401000 1210

4.5 Marking
Fig.-No./Type Type-test
Safety valve (TÜV) approved No. Kdr CE-marking
Manufacturer d0
Notified
body
Approval
Set pressure Adjusting services
Serial-No.
Soft sealed disc: Year of manufacture

E = EPDM -35°C up to 150°C
V = Viton (FPM) -25°C up to 180°C
N = Neoprene -30°C up to 125°C
NB-stamp
Safety valve (ASME) Size (inch) UV-stamp CE-marking
Manufacturer
Notified
body
Fig.-No./Type
Capacity
Fig. 3: Set pressure
Units:
Type test plates SCFM = air
lb/hr = steam
gal/min = water
Address of manufacturer: refer to item 11.0 Warranty / Guarantee
Set pressure
Mechanic No.
BA/BQ
Logo of external approvals
Fig. 4: Body (outlet)

Series with thread connections are marked on the body.
Rev. 0040401000 1210 Page 7

5.0 Installation
The following points should be taken into account besides the general principles governing
installation work:
ATTENTION !
- The interior of valve and pipeline must be free from foreign particles
- Note installation position with reference to flow, see mark on valve.
- Steam line systems should be designed to prevent water accumulation
avoided.
- Connecting bolts for pipe flanges should be mounted preferably from the
counter flange side (hexagon nuts from the valve side).
At DN15-32: If valves should be mounted directly to valves, the upper flange
connecting bolts should be preferably executed with studs and hexagon nuts on
both sides.
- Valve mountings such as actuators, handwheels, bonnets must not be used to
See data sheet for weights.
- The blow-off line shall be sufficiently large to ensure that the internal back-
pressure while blowing-off does not exceed 10% (on reqest max. 15%) of the
set pressure. (Exception: safety valves with metallic bellow for back-pressure
compensation).
- If back pressure exceeds 10% (on request max. 15%) of set pressure, the
safety valve must be fitted with a metallic bellow seal for back pressure
compensation. The maximum back pressure must be specified by the
manufacturer. If necessary a leak detector should be provided to monitor the
back pressure compensating metallic bellow seal, but the leak detector must
not block ventilation.
- The ventilation hole in the bonnet of safety valves with a metallic bellow seal
must remain open as a matter of principle, although in the case of Group I fluids
(PED 97/23/EC) a non-isolatable pipeline must be connected to remove the
medium safely (without back pressure if the bellow seal is damaged. Ventilation
must not be blocked by any leak detector used.
- No pipe sections or screws must protrude into the spring bonnet through the
inspection connection. Blockage hazard!
- The drainage system shall be adequate to remove the condensate.
- Blockage of the drainage system by dirt or foreign bodies shall be avoided.
- Freezing, sticking or blocking of the safety valve must be avoided at all costs. If
necessary use a heating jacket and/or stainless steel bellow with or without a
rupture disk.
- Safety valves shall be installed with upright spindle, not series 950 when
marked, “Einbau nur horizontal (Installation only horizontal)”, then they must be
installed horizontally.
Page 8 Rev. 0040401000 1210
- Flange gaskets shall be fitted concentrically and not restrict the flow cross
section.
- Keep the shaft of the spindle-unit free from paint (open bonnet / cap).
- Blow-off lines shall be laid with gradient.
- The ratio pao/po shall be taken into account when dimensioning the system.
- Safety valves shall be equipped with support tongues to absorb high reaction
forces.
- Pressure losses in the line to the safety valve shall not exceed 3%.
- Ensure that adequate drip pans are used if setting media in Fluid Group
pursuant to PED 97/23/EC.
- Planners / construction companies or operators are responsible for positioning and
- The valves are designed for application, not influenced from weather.
- For application outside or in adverse environments like corrosion-promoting conditions
(sea water, chemical vapours, etc.), special constructions or protective measures are
recommended.
- Refer to appropriate TRD 421, AD2000-A2, DIN, ASME Code rules for piping and
installation.
- Remove transport fasteners and protective caps for inlet and outlet immediately before
installation.
- Water shall be drained from the safety valve and blow-off line via the blow-off line
(drainage points always at the lowest point).
Support
Bellow
Drip pan
Drainage Drainage at lowest point
fig. 5
Rev. 0040401000 1210 Page 9


ATTENTION !
- Touching the valve when it is operating at high (> 50°C) or low (< 0°C) media
- Before putting the valve into operation, check material, pressure, temperature,
direction of flow and also check that the data of the valve are correct for the
plant
(refer to type test plate)
- Remove any test gag from cap and close opening with stopper.
- Remove protective caps and lever lock before putting the valve into operation
- Freezing, sticking or blocking of the safety valve must be avoided at all costs. If
necessary use a heating jacket and/or stainless steel bellow without a rupture
disk. (Note point 5 “Installation”).
- When operating without a blow-off line, medium may spurt from the valve outlet.
Injury hazard!
- Blowing off may generate loud flow noise.
- Medium may be discharged from the ventilation or inspection hole in the spring
bonnet (safety valves with stainless steel bellows and heating valves)
Injury hazard!
- Hot vapour may be discharged if the spring bonnet is open.
Page 10 Rev. 0040401000 1210


Maintenance and maintenance-intervals have to be defined by the operator according to
the requirements.
ATTENTION !
- Too frequent lifting for test purposes can increase wear of the sealing surfaces!
- The safety valve must be lifted from time to time in line with current regulations
(by ≥ 85% from the set pressure) to ensure that the valve works correctly.
(The intervals at which this must be done depends on various factors so that no
generally applicable interval can be specified)
- Original parts only should be fitted as spares as a matter of policy.
- In safety valves with an open spring bonnet there is a danger of being crushed
between the spring windings during lifting and setting.
- Lift the safety valve stem briefly (releasing the lever suddenly) to eliminate slight leaks due
to particles between the seat and disc.
- If this does not eliminate the leak, the sealing surfaces of the seat and/or disc have been
damaged.
This can only be rectified at our works or by an authorised contractor.
- With valves corresponding to Figures 901, 921 and 941, the lever must always be
returned to the original position after lifting the safety valve.
- With Fig. 951 and 961 the lift button must be pressed down again after lifting.
- The manufacturer accepts guarantee liabilities only if tampering by third parties is
prevented.
7.1 Setting instructions
ATTENTION !
The following work must only be carried out by authorised specialist workshops
or at the operator’s own responsibility with monitoring by an independent agency
(e.g. TÜV).
7.1.1 Removing the cap
ATTENTION !
If there is back pressure or during setting/lifting, medium may be discharged from
the open bonnet, or into the adjusting screw area if the bonnet is closed.
ATTENTION !
When changing to the cap without lifting device (series 911, 923, 943), the
spindel cap (pos. 19) must be removed.
Open caps
- Remove slit pin (pos. 40), bolt (pos. 39).
- Extract lifting lever (pos. 41).
- Remove screw (pos. 38).
- Unscrew cap (pos. 29).
Closed caps
- Press lifting lever (pos. 36) towards bonnet (pos. 11) and against stop.
- Unscrew cap (pos. 28).
Rev. 0040401000 1210 Page 11

Closed cap series 960/950
- Remove spring type straight pin (pos. 68)
- Remove lift button (pos. 67) or lifting lever (pos. 36)
- Unscrew cap (pos. 28)
7.1.2 Changing the set pressure “without” spring change
ATTENTION !
- When changing the set pressure in a pressurised system bear in mind vapour
discharge if bonnet is open, in adjusting screw area if bonnet is closed.
- Note spring setting range.
- Check the spring range.
- Spindle (pos. 14) must be held fast by all alterations.
- Loosen lock nut (pos. 21).
- Turn adjusting screw (pos. 17) clockwise to increase and anticlockwise to reduce the set
pressure.
- Secure spring setting by tightening lock nut (pos. 21).
- Assemble lifting device.
7.1.3 Changing the set pressure “with” spring change
ATTENTION !
- Depressurise the system before dismantling or opening the safety valve.
- For removing the cap refer to 7.1.1.

- Extract parallel pin (pos. 20) and lift off the spindle cap (pos. 19).
- Slacken locknut (pos. 21) and relieve spring (pos. 37) by turning adjusting screw (pos. 17)
anticlockwise.
- Unscrew nuts (pos. 8) at flange connection and remove bonnet (pos. 11/42).
Fig. 940: loosen coupling (pos. 61)
Fig. 950/960: loosen bonnet (pos. 11)
ATTENTION !
- With higher set pressures, the two nuts (pos. 8) on the longer studs (pos. 3)
must be removed last and simultaneously!
- Remove top spring-plate (pos. 26) and spring (pos. 37).
- Extract spindle (pos. 14) with disc (pos. 12/12a), guide plate (pos. 4/4a) and bottom
spring-plate (pos. 26).
- Clean seat (pos. 2) and disc (pos. 12).
- Insert spindle (pos. 14) with disc (pos. 12), guide plate (pos. 4), spring-plate (pos. 26) and
different spring (pos. 37).
Page 12 Rev. 0040401000 1210

- when carrying out any adjustment work hold the spindle (pos. 14) firm to prevent it
twisting.
ATTENTION !
- Torques must be observed:
M10 16-25 Nm screw joint BR940 100 Nm
M12 30-40 Nm screwed seat BR940 180 Nm
M16 70-90 Nm bonnet BR950/960 60 Nm
M20 150-175 Nm
- Check spring marking in accordance with manufacturer’s data.

- Note spring setting range.
- Change seals.
- Fit bonnet (pos. 11/42) and reset the set pressure; make sure spring setting range is
appropriate.
- Secure spring setting by means of lock nut (pos. 21).
- Assemble lifting device.
- If necessary, replace both spring plates (pos. 26) and use longer studs (pos. 3) when
fitting a spring for a higher set pressure.
- Further information obtainable from the manufacturer.
Only for series 900

ATTENTION !
When changing the set pressure and fitting a new spring, note that safety valves
with set pressures between 0.2 and 1.5 bar have a greater lift.
Therefore:
Set pressure in the range Spring change only in
the range
0.2 to 1.5 bar 0.2 to 1.5 bar
> 1.5 bar > 1.5 bar
Only for series 950:

ATTENTION !
Safety valves for horizontal application, must also to be set in a
horizontal position (≤ 4.9 bar).
Rev. 0040401000 1210 Page 13

7.2 Representation
SAFE-TCS
SAFE-TCP
SAFE-TC
Bellow
Closed cap
Open cap
fig. 6
Page 14 Rev. 0040401000 1210

8.0 Troubleshooting
Instructions.
ATTENTION !
-
It is essential that the safety regulations are observed when identifying faults.

“9.0 troubleshooting table”, the supplier or manufacturer should be consulted.

ATTENTION !

Safety valve does not Flange covers not removed. Remove flange covers.
respond,
Test gag still in place. Remove test gag.
no flow
Spring blocked. Remove pipe or screw projecting into
bonnet through inspection connection.
Set pressure too high. Reset (point 8.1) or replace the safety
valve.
Stainless steel bellow defective, Replace the safety valve.
no back-pressure compensation.
Back-pressure not taken into account. Reset (point 8.1) or, if necessary,
replace the safety valve.
The use of a stainless steel bellow to
compensate for back-pressure should
be considered.
Medium viscous or sticky Use bellow / heating jacket. Insert
rupture disc upstream if necessary.
The valves and piping must be Heating !

protected against freezing and
solidifying media.
Stem cannot be lifted. Pressure less than 85% of set It must be possible to lift the spindle at
pressure. over 85% of the set pressure.
Safety valve seat leaking. Working pressure higher than 90% of Working pressure must be less than
set pressure. 90% of the set pressure.
At low pressures: lever not in neutral Press lever into neutral position
position with closed cap. (towards bonnet).
Safety valve flattering. Refer to separate point “Flattering”.
Medium contaminated; foreign body Raise spindle briefly or, if necessary,
between seat and disc. replace safety valve.
Use of a soft sealing disc should be
considered.
Rev. 0040401000 1210 Page 15


Flange broken. Damage during transport. Replace safety valve.
Flange bolts not evenly tightened. Replace safety valve.
Transfer of forces such as bending or Install free of tension.
torsional forces.
Pressure surges. Safety valve not installed at highest Install safety valve at highest point.
point.
Valve drainage inadequate or not fitted. Install drainage system a required by
regulations.
Valve constantly blows off. Transport fastening not removed. Remove transport fastening (red screw
above cap, Figure 990).
Spring corroded by medium and Replace safety valve.
broken. In the case of vapour, select open cap
or bonnet if possible.
Injury owing to medium. Danger of injury from medium (e.g. Replace safety valve.
liquids) emerging from valve. Select design with closed bonnet and
cap.
Install a guard if necessary.
Injury from vapour discharge Install a guard if necessary
(open bonnet / cap)
Flattering. Pressure loss >3% in line to valve. Reduce resistance by chamfering or
radius in connection socket. Select
larger line if necessary.
Poor welding (root pass), gaskets at Change conditions.
inlet and outlet flanges too small or not
concentric.
Safety valve capacity too high. Install smaller safety valve.
Burner capacity too low. Install smaller safety valve.
Blow-off line too long or diameter too Use larger diameter or back-pressure
small. compensation by stainless steel
bellow.
Inlet and/or outlet socket too small. Install with dimensions larger than DN
of inlet and outlet lines.
Back-pressure higher than 10%. Install stainless steel bellow for
pressure compensation.
Capacity too low. Safety valves not applied unsuitable for Select and install suitable safety
plant conditions. valves.
Safety valve not applied in line with Adjust conditions.
current DIN, AD, TRD, etc. rules.
Page 16 Rev. 0040401000 1210


ATTENTION !
media.

appointed by us.
The manufacturer will accept warranty liability only if there has been no third party
tampering.

Rev. 0040401000 1210 Page 17


Mergelheide 56-60, D-33756 Schloß Holte-Stukenbrock
as defined by
the Pressure Equipment Directive 97/23/EC
that according to the above mentioned Pressure Equipment Directive (PED) the below listed
products comply and have been approved according to Module H1 and also EC type test according
to module B+D through Lloyd´s Register Quality Assurance GmbH (BS-No. 0525),
Am Sandtorkai 41, D-20457 Hamburg.
Certificate-No: 50003/2
Safety valves Safety valves

SAFE series 900 SAFE-P series 920
Type 901,911,912,902,903,904,990 Type 921,922,923,924
Applied standards : Applied standards :
DIN EN ISO 4126-1 DIN EN ISO 4126-1
AD 2000 Code of Practice A2 AD 2000 Code of Practice A2
- Cast iron with spher. graphite - Cast steel
- Cast steel TRD 421, TRD 721
TRD 421, TRD 721 VdTÜV 100, DIN 3840
VdTÜV 100, DIN 3840
ASME Code Section VIII-Div. 1
Safety valves Safety valves
SAFE-TC series 940 SAFE-TCP/TCS series 950/960
Type 941,942,943,945,946 Type 951,952,953,961,962,963
Applied standards : Applied standards :
DIN EN ISO 4126-1 DIN EN ISO 4126-1
- Cast iron with spher. graphite - Cast iron with spher. graphite
- Cast steel - Cast steel
TRD 421, TRD 721 VdTÜV 100, DIN 3840
VdTÜV 100, DIN 3840
...................................................
Page 18 Rev. 0040401000 1210

Westfalia Separator
Geschäftsbereich
Mechanische Trenntechnik

Installation and Maintenance Manual
für / for
Druckgesteuertes 3/2-Wege-Ventil
Pressure controlled 3/2-way valve
No.: 9085-9000-000
Edition: 1107
Westfalia Separator
Inhaltliche Änderungen vorbehalten!
Für Anmerkungen und Vorschläge zur Verbesserung der Dokumentation sind

die Verfasser stets dankbar. Diese können an
Westfalia Separator Mineraloil Systems GmbH
Werner-Habig-Str. 1
D-59302 Oelde
gerichtet werden.
Werner-Habig-Str. 1
D-59302 Oelde
9085-9000-000 / 1107
Westfalia Separator
Fig. 1
• Bitte lesen Sie vor Installation Ihrer Armatur diese Betriebs- und Wartungsanleitung
sorgfältig durch.
• Die Installation und Wartung darf nur durch qualifiziertes Personal durchgeführt wer-
den.
• Bitte beachten Sie die in dieser Anleitung aufgeführten Sicherheitshinweise!
• Before installing and maintaining your valve, please read this manual carefully.
• Installation and maintanance is allowed for skilled employees only.
• Please pay attention to the safety advices!
9085-9000-000 / 1107
Westfalia Separator
Anforderungen an Ersatzteile
• Nur Original-Ersatzteile von Westfalia Sepa-

rator verwenden.
Der Einsatz von nichtoriginalen Teilen führt zu:
– Sicherheitsrisiken,
– verringerter Haltbarkeit und Verfügbarkeit,
– erhöhtem Servicebedarf.
Realisiert sich ein Sicherheitsrisiko beim Einsatz
von nichtoriginalen Ersatzteilen, ergeben sich
Fig. 2 unter Umständen hierdurch auch strafrechtliche
Folgen für die handelnden Personen. Westfalia
Separator übernimmt in diesen Fällen keinerlei
Haftung oder Gewährleistung.
Demands relating to spare parts

Separator.
– safety risks,
Fig. 3 for the responsible persons. In such cases,
ranty claims.
9085-9000-000 / 1107
Westfalia Separator
Anforderungen an Ersatzteile .....................................................4

Demands relating to spare parts ................................................4
1 DEUTSCH 7
Zu dieser Anleitung .......................................................8

Abkürzungen und Symbole ............................................................8
Leistungsbeschreibung ................................................9
Bestimmungsgemäße Verwendung ...............................................9
Lagerung, Transport, Entsorgung ..................................................9
Allgemeine Einsatzbedingungen ....................................................9
Gerätebeschreibung....................................................10
Notbetätigung...............................................................................11
Ersatzteilsets................................................................................12
Tätigkeitsbeschreibung ..............................................14
Installation und Inbetriebnahme eines druckgesteuerten
3/2-Wege-Ventils ...............................................................14
2 ENGLISH 15
This manual..................................................................16
Shortcuts and symbols .................................................................16
Specification of service...............................................17
Intended usage ............................................................................17
Storage, transport, disposal .........................................................17
Terms of general application ........................................................17
9085-9000-000 / 1107
Westfalia Separator
Device description ......................................................18

Emergency operation ...................................................................19
Spare Parts ..................................................................................20
Initial operation and maintenance..............................22

Installation of a pressure controlled 3/2-way valve.......................22
Formular zur Ersatzteilanfrage oder -bestellung

Fax form for spare parts inquiries or orders
9085-9000-000 / 1107
Westfalia Separator
1 DEUTSCH
9085-9000-000 / 1107
Westfalia Separator
Zu dieser Anleitung
Ziel der Anleitung

Die vorliegenden Informationen ermöglichen es Ihnen, die Armatur fachgerecht zu installieren und
zu warten. Die Anleitung richtet sich an technisch qualifiziertes Personal. Es wird vorausgesetzt,
dass bestimmtes Fachvokabular verstanden wird und dass technische Zeichnungen gelesen werden
können.
Sollte dies nicht der Fall sein, informieren Sie bitte Ihren zuständigen Kundenbetreuer.
Achtung!
Achtung! Bitte
Heiße
lesen!
Oberfläche!
Werkzeug Vorsicht!
notwendig Spannung
Zu Ihrer Dokumente

gefahr! Anleitung
Betriebsstoff
notwendig
9085-9000-000 / 1107
Westfalia Separator
Die druckgesteuerte 3/2-Wege Zulaufarmatur ist zum Einsatz im industriellen Bereich geeignet. Die
Armatur ermöglicht das Steuern gasförmiger und flüssiger Medien. Die Gehäuse- und Dichtmateria-
lien müssen für das eingesetzte Medium und den angegebenen Temperaturbereich geeignet sein.
Verletzungsgefahr!
Hineinführen von Körperteilen und Gegenständen in das Ventil kann zu schweren Verletzun-
gen führen und sollte unbedingt vermieden werden!

Die Produkte sind i.d.R. durch Umverpackungen vor äußeren Einflüssen wie Feuchtigkeit oder
Schmutz geschützt. Wir empfehlen, diese Umverpackung erst kurz vor Montagebeginn zu entfernen,
um die Geräte vor Verunreinigungen zu schützen.
Bei Einlagerung ist darauf zu achten, dass die Geräte trocken und schmutzfrei untergebracht wer-
den.
Auf die Handhabung beim Transport können wir nur mit Ihrer Hilfe Einfluss nehmen – bitte infor-
mieren Sie uns unverzüglich, wenn die Ware bereits mit beschädigter Verpackung bei Ihnen eintrifft!
Die Kontrolle der Produkte muss unmittelbar nach Wareneingang erfolgen und sollte eine Prüfung
der technischen Parameter und eine Sichtprüfung beinhalten. Verdeckte Mängel sind unverzüglich
nach Entdeckung zu rügen, andernfalls gilt die Ware als abgenommen.
Warenmängel oder Abweichungen der Menge müssen spätestens 7 Tage nach Erhalt der Wa-
re schriftlich angezeigt werden, andernfalls erlischt der Gewährleistungsanspruch!
Rohrleitungen sollten vor Einbau, spätestens jedoch vor Inbetriebnahme durchgespült werden. Au-
tomatisierte Armaturen bedürfen einer besonderen Beachtung bei der Inbetriebnahme! Diese Geräte
können im Werk nur unter Werkstattbedingungen getestet und eingestellt werden. Sicherheitsstel-
lungen sollten gezielt simuliert und getestet werden. Die Endlagen (offen/geschlossen) müssen ü-
berprüft und ggf. nachjustiert werden! Zusätzliche Wegschalter oder andere elektrische Geräte zur
Stellungsrückmeldung ebenfalls auf richtige Justierung überprüfen!
9085-9000-000 / 1107
Westfalia Separator
Gerätebeschreibung
1 Einstellschraube d. Drossel
2 Eingang
3 Ausgang (stromlos offen)
4 Ausgang nach Betätigung
5 Zylinder
6a Sicherungskappe
6b Notbetätigung [Druckventil] (SW 19)
7 Befestigungsbohrungen
8 Schalldämpfer
9 Stecker für Magnetventil
10 Magnetventil
11 Notbetätigung [Magnetventil]
12 Lufteinlass
13 Temperaturfühler PT100
14 Rückschlagventil
9085-9000-000 / 1107
Westfalia Separator
Notbetätigung
Sollte der Versorgungsdruck des Ventils einmal ausfallen, gehen Sie bitte wie folgt vor:
Transparente Kappe (6a) am oberen Ende des 3/2-Wege-Ventils abschrauben.

Sechskantmutter [SW 19] (6b) bis zu deutlich spürbarem Widerstand (ca. 10mm) einschrau-
ben.
Ventil ist nun geschaltet. Vergessen Sie nicht, nach der Instandsetzung der Druckluftversor-
gung die Notbetätigungsschraube zurück in ihren Ursprung zu versetzen
Sollte die Versorgungsspannung für das Magnetventil (10) einmal ausfallen, gehen Sie bitte
wie folgt vor:
Mit Schraubendreher die Notbetätigung (11) um 180° drehen, bis das Ventil öffnet.
Die Stellung der Notbetätigung ist mit den Buchstaben o = geöffnet (open) und c = geschlossen
(closed) gekennzeichnet. Im Lieferzustand ist die Notbetätigung auf die Position „geschlossen“ ein-
gestellt („c“ steht rechts).
Für die normale Funktion des Magnetventils muss die Notbetätigung wieder zurückgesetzt
werden.
Das Bild „A“ zeigt die geschlossene Stellung, das Bild „B“ die geöffnete Stellung
9085-9000-000 / 1107
Westfalia Separator
Ersatzteilsets
Druckgesteuertes 3/2-Wege-Ventil Teil-Nr. 0018-7621-000
(vollständig)
Rückschlagventil Teil-Nr. 0018-7621-920

(Pos. 14)
Zylinder (Luft) Teil-Nr. 0018-7621-930

(Pos. 5)
Klarsichtkappe mit Dichtung Teil-Nr. 0018-7621-940

(Pos. 6a)
Pilotventil mit Kabelkopf, Teil-Nr. 0018-7621-600

Skintopverschraubung und (Pos. 8, 9, 10)
Schalldämpfer mit montierter
Winkelverschraubung1/8 – DN8 und
montierter lösbarer Verschraubung
1/4 - 1/8 mit Drossel
Doppel PT100 Teil-Nr. 0001-1579-400

(Pos. 13)
9085-9000-000 / 1107
Westfalia Separator
Satz Dichtungen mit Klarsichtkappe Teil-Nr. 0018-7621-950

(Pos. 15-28)
15 Kappe
16 Spindel
17 Buchse
18 O-Ring
19 O-Ring
20 O-Ring
21 Kolben
22 Buchse
23 Nutring
24 Spindel-Wellendichtung
25 O-Ring
26 O-Ring
27 O-Ring
28 O-Ring
Spindel (16) fertig montiert, bestehend

aus Positionen:
26 O-Ring
29 Mutter
30 Sitzdichtung
31 Scheibe
9085-9000-000 / 1107
Westfalia Separator
Installation und Inbetriebnahme eines druckgesteuerten 3/2-Wege-Ventils
Das Ventilgehäuse mit den Flanschdichtungen vorsichtig

zwischen die zuvor angebrachten Flansche schieben.
Bitte achten Sie darauf, dass die verwendeten Dichtungen für das Durchfluss-Medium geeig-
net sind!
Die Flanschbohrungen zueinander ausrichten und passende

Schrauben oder Stehbolzen in die Bohrungen stecken bzw.
einschrauben.
Die Flansche mit passenden Schrauben fest und kreuzweise

befestigen bzw. passende Muttern fest und kreuzweise auf die
Stehbolzen aufschrauben.
9085-9000-000 / 1107
Westfalia Separator
2 ENGLISH
9085-9000-000 / 1107
Westfalia Separator
This manual
This information enables you to install and maintain your valve. This manual is for skilled employees
only. We assume that you are familiar with the common valve terminology and that you can read
technical documents.
If you don’t meet these expectations please inform your personal customer advisor!
Attention!
Danger!
Please read
Hot surface!
carefully
Tools Danger!
necessary Voltage.


Supply items
needed!
9085-9000-000 / 1107
Westfalia Separator
Intended usage
These pressure controlled valves are suitable for industrial use. The valve enables the control of
gaseous and liquid media. The housing and sealing compounds must be suitable for the assigned
medium and temperature range.
Danger of injury! 1
Do not put parts of your body or articles into the valve. This can cause heavy injuries and
should be absolutely avoided!

The products are protected by packaging against external influences such as humidity or dirt. We
recommend that the packaging is removed only briefly before the beginning of assembly in order to
protect the devices against impurities.
Make sure, that the devices are stored dry and dirt-free.
Influencing the handling during transport requires your assistance – please inform us immediately
if the commodity arrives with damaged packaging! An examination of the technical parameters and a
visual check of the products should take place immediately after delivery. Notice on latent defects is
to be given immediately after detection. Subsequent complaints will not be accepted.
Deficient goods or divergences of the amount must be indicated at the latest 7 days on re-
ceipt of the products in writing, otherwise the guarantee claim will run out!

It is advised to clean the valve and piping before initial use. Automated valves need special attention!
These devices can be tested under workshop conditions only. Security positions should be system-
atically simulated and tested. The final positions must be checked (open/closed) and re-adjusted if
necessary! Additional switches or other electric devices for the position feedback must be likewise
checked regarding correct settings.
9085-9000-000 / 1107
Westfalia Separator
Device description
1 Adjusting screw
2 Input
3 Output (normally open)
4 Output after operation
5 Cylinder
6a Safety cover
6b Emergency operation [valve] (SW 19)
7 Fixing hole
8 Absorbing duct
9 Connector for solenoid valve
10 Solenoid valve
11 Emergency operation [solenoid valve]
12 Air input
13 Temperature sensor PT100
14 Non-return valve
9085-9000-000 / 1107
Westfalia Separator
Emergency operation
In case of a supply pressure deficiency at the valve, please proceed as follows:
Unscrew transparent cap (6a) at the upper end of the valve.

Screw in hexagon nut [SW 19] (6b) up to clearly noticeable resistance (app. 10mm).
Valve is switched. Do not forget to screw back the emergency operating screw into its origi-
nal position when the compressed air supply is restored.
In case of a supply voltage deficiency at the solenoid valve, please proceed as follows:
Turn the manual override (11) about 180° using a screwdriver until the valve opens. The posi-
tion of the manual override is marked with o = open and c = closed. Delivery condition is closed
(mark “c” on the right side).
Reset the manual override to restore normal function.
Picture „A“ shows the closed and picture B the open position
9085-9000-000 / 1107
Westfalia Separator
Spare Parts
Pressure controlled 3/2-way valve Part-No. 0018-7621-000
(complete)
Non-return valve Part-No. 0018-7621-920

(Pos. 14)
Cylinder (air) Part-No. 0018-7621-930

(Pos. 5)
Transparent cap with sealing Part-No. 0018-7621-940

(Pos. 6a)
Pilot valve with cable head, Part-No. 0018-7621-600

skintop connection and ab- (Pos. 8, 9, 10)
sorbing duct with mounted elbow
union 1/8 – DN8 and
assembled removable
screwing 1/4 - 1/8
with air regulation
Double PT100 Part-No. 0001-1579-400

(Pos. 13)
9085-9000-000 / 1107
Westfalia Separator
Sealing set with transparent cap Part-No.. 0018-7621-950

(Pos. 15-28)
15 cap
16 shaft
17 nut
18 o-Ring
19 o-Ring
20 o-Ring
21 piston
22 nut
23 lip seal
24 shaft sealing
25 o-Ring
26 o-Ring
27 o-Ring
28 o-Ring
Shaft (16) with mounted parts:
26 o-Ring
29 nut
30 seat sealing
31 disc
9085-9000-000 / 1107
Westfalia Separator
Initial operation and maintenance
Installation of a pressure controlled 3/2-way valve
Installation in unpressurised state only!
Push the valve housing with the flange seals carefully between the
flanges.
Please pay attention to the fact that the used sealing compounds are suitable for the flowing
medium!
Align the flange drillings to each other and put suitable screws into
the drillings
Fix the nuts crosswise and firmly onto the screws.
9085-9000-000 / 1107
Westfalia Separator
9085-9000-000 / 1107
Westfalia Separator
Seite / page: 1-2

Faxformular - Fax Form
(vor Benutzung kopieren! – Copy before use!)
zur / for
Ersatzteilanfrage Ersatzteilbestellung
Spare part inquiries Spare part orders
An / To
Am Neuländer Gewerbepark 6
D-21079 Hamburg (Germany)
Fax-No.: +49 (0) 40-7380585
Besteller / Orderer
Firma / Company
Name
Straße, Haus-Nr.
Street, house no.
PLZ, Ort / ZIP, City
Telefon / Phone
Fax
Lieferanschrift (falls abweichend) Rechnungsanschrift (falls abweichend)

Delivery address (if different) Invoice address (if different)
Firma Firma
Company Company
Name Name
Straße, Straße,
Haus-Nr. Haus-Nr.
Street, Street,
house no. house no.
PLZ, Ort PLZ, Ort
ZIP, City ZIP, City
Telefon Telefon
Phone Phone
Fax Fax
Gewünschte Lieferzeit:
Desired delivery time:
Kommentar:
Remarks:
Ort, Datum / Place, Date Firmenstempel, Unterschrift / Company stamp, Signature
9085-9000-000 / 1107
Westfalia Separator
Seite / page: 2-2

Faxformular - Fax Form
(vor Benutzung kopieren! – Copy before use!)
zur / for
Ersatzteilanfrage Ersatzteilbestellung
Spare part inquiries Spare part orders
WICHTIG! Bei Anfrage oder Bestellung unbedingt angeben:

IMPORTANT! When submitting your inquiry or order, be sure to state:
WSM-Auftrags-Nr. Serien-Nr. Typ

WSM Order No.: Serial No. Type
Kundenauftrags-Nr.
Customer Order No.
Pos. (falls
vorhanden) Bestellnummer Menge Bezeichnung
Item (if Part-No. Qty. Description
available)
Ort, Datum / Place, Date Firmenstempel, Unterschrift / Company stamp, Signature
9085-9000-000 / 1107
Westfalia Separator
9085-9000-000 / 1107
Westfalia Separator
9085-9000-000 / 1107
Westfalia Separator
Westfalia Separator Mineraloil Systems GmbH ● Werner-Habig-Straße 1 ● D-59302 Oelde (Germany)

Tel.: +49 (0) 25 22/77-0 ● Fax: +49 (0) 25 22/77-23 94 ●
Operating Instructions 0507/02_EU-ML_00893047
Steuer- und Regeltechnik Berlin, Ph. (0 30) 67 97 17-0 China: Shanghai, Ph. (8621) 58 68 21 19 Norway: 2013 Skjetten, Ph. (63) 84 44 10
Christian-Bürkert-Str. 13-17 Frankfurt, Ph. (0 61 03) 9 41 40 Czech Republic: 60200 Brno, Ph. (543) 25 25 05 Philippines: Paranaque City, Ph. (02) 776 43 84
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Operating Instructions 0507/02_EU-ML_00893074
Berlin, Ph. (0 30) 67 97 17-0 China: Shanghai, Ph. (8621) 58 68 21 19 Norway: 2013 Skjetten, Ph. (63) 84 44 10
Frankfurt, Ph. (0 61 03) 9 41 40 Czech Republic: 60200 Brno, Ph. (543) 25 25 05 Philippines: Paranaque City, Ph. (02) 776 43 84
Hannover, Ph. (05 11) 902 76-0 Denmark: 2730 Herlev, Ph. (44) 50 75 00 Poland: PL-02-904 Warszawa, Ph. (022) 840 60 10
Dresden, Ph. (03 59 52) 36-300 Estonia: EE-12915 Tallin, Ph. (372)644 06 98 Portugal: Sales office in Spain, Ph. (21) 21 28 490
Sales Centre
International
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München, Ph. (0 89) 8 29 22 80 France: 67220 Triembach au Val, Ph. (0388) 58 91 11 South Africa: Millenium Business Park, Ph. (011) 574 60 00
info@de.buerkert.com
Steuer- und Regeltechnik Stuttgart, Ph. (07 11) 451 10-0 Hong Kong: Kwai Chung NT, Ph. 24 80 12 02
D-74653 Ingelfingen
India: Chennai 600 028, Ph.(044)52 30 34 56 Sweden: 21120 Malmö, Ph. (040) 664 51 00
Chr.-Bürkert-Str. 13-17
Australia: Seven Hills NSW 2147, Ph. (02) 1300 888 868 Italy: 20060 Cassina De ‘Pecchi (Mi), Ph. (02) 95 90 71
Austria: 1150 Wien, Ph. (01) 894 13 33 Japan: Tokyo 166-0004, Ph.(03) 53 05 36 10 Taiwan: Taiwan 115, Ph.
Bürkert Fluid Control System
E-mail: info@de.buerkert.com
Fax + 49 (0) 7940 - 10 91 448
Tel. + 49 (0) 7940 - 10 91 111
Belgium: B-2110 Wijnegem, Ph. (03) 325 89 00 Korea: Seoul 153-811, Ph. (02) 34 62 55 92 Turkey: TR-Yenisehir-lzmir, Ph. (0232) 459 53 95
Brazil: 04715-005 São Paulo - SP, Ph. (011) 51 82 00 11 Malaysia: 11960 Penang, Ph. (04) 64 350 08 United Kingdom: Stroud, Glos, GL5 2QF, Ph. (01453)731353
Canada: Oakville, Ontario L6L 6M5, Ph. (905) 847 55 66 Netherlands: NL-3542 DP Utrecht, Ph. (0346) 58 10 10 USA: Irvine, CA 92614, Ph. (949) 223 31 00
Germany / Deutschland / Allemange
Les adresses se trouvent sur internet sous :

www.burkert.com Bürkert / Company / Locations
Die Kontaktadressen finden Sie im Internet unter:
Contact addresses can be found on the internet at:
Contact addresses / Kontaktadressen
Non-Return valves,
Swing-Check valves
Mounting and Operating Manual

Impressum
This documentation may neither be altered, expanded, reproduced nor passed to third parties without the written
aggreement of END-Armaturen GmbH & Co. KG. This restriction also applies to the corresponding drawings.
END-Armaturen GmbH & Co. KG has the right to change parts of the non-return valves / swing check valves
at any time without prior or direct notice to the client. The contents of this publication are subject to change
without notice.
The products are specified by the statements in this documentation; no assurance of the properties is given.

Telefon: 05731 / 7900 - 0
Telefax: 05731 / 7900 - 80
E-Mail: post@end.de
Edition: 11/02
Contents
Contents
1 Foreword 4
2 General Advice 5
2.1 Validity 5
2.3 Complaints 5
2.4 Guarantee 5
3 Safety Advice 7
3.1 Personal advice 7
3.1.1 Safety advices for mounting 7
3.1.3 Safety advice for maintaining / repairing 8
3.2 Device safety 9
4 Name-plate 10
5 Non-Return valves, Swing-Check valves 11

5.1 General 11
5.3 Operation 11
5.4 Mounting / Disassemble 11
5.4.1 Mounting with threaded connection 12
5.4.2 Mounting with welded connection 12
5.4.2.1 Disassemble of the bonnet and the inner parts 13
5.4.2.2 Welding the body between pipes 13
5.4.2.3 Mounting of the bonnet and the inner parts 14
5.4.3 Mounting of the valve with flanged connection 15
5.5 Maintenance 15
Foreword
1 Foreword
Dear customer,
necessary for you to be able to carry out the mounting and adjustment of the non-return valves /
swing-check valves rapidly and correctly.
notes.
Only instructed and qualified mechanician should mount, adjust or maintain the non-return valves
/ swing-check valves.
If you have any questions in relation to the non-return valves / swing-check valves we shall be
pleased to answer them.
manual.
Yours
General Advice
2 General Advice
2.1 Validity
This mounting and installation manual is valid for the standard versions of the non-return valves /
swing-check valves and their variants.
Please check directly after delivery the non-return valves /swing-check valves for any transport
damages and deficiencies and with reference to the accompanying delivery note the number of
parts.
2.3 Complaints

2.4 Guarantee
For our non-return valves / swing-check valves we give a guarantee period in accordance with
the sales contract.
Safety Advice
3 Safety Advice
Depending on the technical circumstances and the time under and at which the non-return valves
/ swing-check valves are mounted, adjusted and commissioned, you must take into account parti-
cular safety aspects in each case!
If, for example, a non-return valve / swing-check valve works a slide in an operational chemical
plant, the potential hazards of commissioning have another dimension from that when this is only
being carried out for test purposes an a „dry“ part of the plant in the assembly room!
Since we do not know the circumstances at the time of the mounting/adjustment/commissioning,

you may find advices on hazards in the following descriptions which are not relevant to you.
Please observe (only) the advices which applies to your situation!
3.1 Personal advice
3.1.1 Safety advices for mounting
We wish to point out expressly that the mounting, adjusting and at accessories the pneumatical
and eletrical installation of the butterfly valves must be carried out by trained specialist person-
nel having mechanical, pneumatical and electrical knowledge!
Secure that the machine / plant come up to the Machinery Directice after the mounting and instal-
ling of the ball valves.
Switch off all the devices / machines / plant affected by mounting or repair.
will cause potential danger.
If appropriate, in the event of a fault in the butterfly valve (in a plant which is in operation) inform
the shift forman / safety engineer or the works manager without delay about the fault, in order,
for example, to avoid an outflow / overflow of chemicals or the discharge of gases in good time
by means of suitable measures!
Before mounting or repairing, remove the pressure from pneumatic / hydraulic devices / machi-
nes / plant.
machines / plant.
carrying out the mounting / repair work.
Check the correct functioning of the safety equipment (for example the emergency push off but-
tons/ safety valves, etc)!
As a result of the starting of the non-return valves / swing-check valves the flow of gases, steam,
liquids, etc. may be enabled or interrupted! Satisfy yourself that, as a result of the starting or the
test adjustment no potential hazards will be produced for the personnel or the environment!
Safety Advice
If necessary, set up warning signs in order to prevent the inadvertent starting up or shutting down
of the device / machine / plant.!
By ending the adjustment check the correct function and should the occasion arise the position
of the non-return valve / swing-check valve.
Check the function of the limit switches (option)!
Check, whether the armature will be closed totally, if the control signals the appropriate limit
stop!
Through suitable measures, prevent links being trapped by moving actuating elements!
valves)!
this documentation!
Adjusting switchs on ball valves with options (e.g. actuators, solenoid valves, limit switches)
there is the risk that live parts (230 V AC~) can be touched!
Therefore the adjustments must be carried out only by the electrican or a person having adequate
training, who is aware of the potential hazard!
3.1.3 Safety advice for maintaining / repairing
Do not carry out any maintenances / repairs if the non-return vales / swing check valves will be
under pressure.
Before disassembling the armature some essential points should be clarified!

• Will the non-return valves / swing-check valves to be disassembled be replaced by
another immediately?
• If appropriate, does the production process of the plant needed to be stopped?
• Is it necessary to inform specific personnel about the disassmbly?
If necessary, inform the shift foreman/ safety engineer or the manager about the maintenance
or repair without delay in order, for example, to avoid an outflow/ overflow of chemicals or a
discharge of gases in good time by means of suitable measures!
You have to relieve the pressure in the pipes in which the butterfly valve is mounted.
Switch off pilot pressure and the power supply and relieve the pressure in the pipes.
If necessary set up warning signs in order to prevent

• the inadvertent starting up of the devices/machines/plants in which the armature is
mounted
• the switching on of pilot medium supply, pilot power supply and/or the power supply
of actuators and accessories.
In case of defect in the non-return vales / swing check valves make contact to the supplier. The
telephone number will be found on the back cover of these mounting and installation manual.
Safety Advice
If you ascertain a damage of the non-return vales / swing check valves, isolate the device from
the mains. Please observe the safefy advices.
Do not mount, start or adjust the non-return vales / swing check valves if itself, the pipes or a
mounted actuator will be damaged.
After the maintenance or repair check the right function of the non-return vales / swing check
valves and the tightness of the pipe connections.
3.2 Device safety
The non-return valves / swing-check valves

• are quality products which are produced in accordance to the recognized industrial
regulations.
• left the manufacturer`s work in a perfect safety condition.
with the description in these instructions, technically correctly and with the greatest possible
precision .
We assume, as a trained specialist you are having mechanical and electrical knowledge!
Satisfy yourself that the non-return vales /swing check valves will only be used within their
admissible limiting value (see the technical data) .
The non-return vales / swing check valves must be used only for a purpose corresponding to their
construction!
The non-return vales / swing check valves must be used within the values specified in the tech-
nical data!
The operating of the non-return vales / swing check valves outside the nominal temperature
range could destroy the sealings and the bearings.
The operating of the non-return vales / swing check valves outside the nominal pressure range
could destroy the inner parts and the body.
Do not mount, start or adjust the non-return vales / swing check valves if itself, the pipes or a
mounted actuator will be damaged.
After the maintenance or repair check the right function of the non-return vales / swing check
valves and the tightness of the pipe connections.
Name-plate
4 Name-plate
In some cases the armatures/valves will be provided with a nameplate, which permitts a definite identification
of the armatures/valves and shows the most important technical data to you. The name-plate should not be
displaced or changed.
END-Armaturen GmbH & Co. KG KG

+49 (0)5731 - 7900-0 www.end.de
www.end.de
Art.Nr.: ZA310028-ED620632
Serie:
Serial: 313857
Betriebsdruck
Pressure range(PS):
(PS): 16 bar
16 bar
Steuerdruck:
Pilot pressure: 6-8 6-8bar bar
Temperatur
Temperature(TS): -30°C
range (TS): ... +180°C
-30°C ... +180°C
Größe (DN):
Size (DN): 50 / G2"50 / G2"
Prüfdruck (PT): (PT): 60 bar 60 bar
Testing pressure
Fluidgruppe:
Fluidgroup: 1 1
Herstellung:
Date of manufacturing:13.11.200211.2002
0062
Fig. 4.1 - name-plate
Art.No. article number of the valve / armature

Serial order- or production- number
Pressure range (PS) max. admisable working pressure of the valve / armature [bar]
Pilot pressure recommend pilot pressure for correct function of the valve / armature [bar]
(only at pneumatic actuated valves / armatures)
Size (DN) connecting size of the valve / armature
Testing pressure (PT) testing pressure of the body of the valve / armature
Fluidgroup allowed fluidgroup of the valve / armature
Date of manufacturing month and year of manufacturing of the valve / armature
Non-Return valves, Swing-Check valves
5 Non-Return valves, Swing-Check valves
5.1 General
Before you mount /disassemble, adjust or commission a non-return valve or a swing-check valve
you must have read the
Safety advice
If you have not read the safety advices until now please read these important advices now and
turn back to this point.
Non-return valves and swing-check valves are used to prevent the back-flow of media.
It should only be used clean liquids and gases, on which the material of the valves and the material
of the sealings will be resistant. Pollution or using outside the nominal pressure range and/or the
nominal temperature range should causes damages on the valves especially on the seals.
5.3 Operation
Non-return valves and swing-check vales need no special operation .
5.4 Mounting / Disassemble
The mechanical mounting is identical in all variants. It differs only by the type of connection.
Observe the flow direction which is specified on the valve body. The installation of a swing-check
valves will have take place that the flap of the swing-check valve will close by the force of gravity
automatically.
Please observe that that the installation of the swing-check valve / non-return valve will have
influence on the opening pressure.
Remove all transport safety devices (e.g. plugs or caps). Observe that there won`t be any parts of
the package or other pollution in the armature.
Before mounting swing-check valve / non-return valve clean up the pipes. Pollution will reduce the
safety and the duration of life of the armature.
o.k. o.k.
Fig. 5.1 - non-return valve, swing-check valve, installation (Fig.: Art. TR100025).
Avoid stress in case of non align pipes.
5.4.1 Mounting with threaded connection
Before lay on sealing compounds, check the hardly screwing by the pipes into the valve body.
Lay on the correct sealing compounds on the pipes end. By using PTFE-ribbon or hemp sealings
observe the screw direction. Don`t use sealing compounds which are not prescribed for your emp-
loyment.
Screw the pipes into the connection ends of the valve.
tends to harden it.
sealing compound
harden!
o.k.
flow direction
Fig. 5.2 - non-return valves, swing-check valves, mounting with threaded connection (Fig.: Art. BH120025)
5.4.2 Mounting with welded connection
Before welding the valve between the pipes you have to disassemble the bonnet of the non-return
valve first, to prevent the damage of the sealings.
Non-Return valves, Swing-check valve
5.4.2.1 Disassemble of the bonnet and the inner parts
Clamp the valve between a vice carefully. By using guard plates you can prevent the damage of
the ends of the valve body.
Loosen the bonnet with a fit spanner.
Screw the bonnet out of the body. By doing this be very careful, because there will be a resilience
on the bonnet. Take the spring and the inner part out of the bonnet and put the parts aside.
resilience
Fig. 5.3 - non-return valves, swing check valve, disassembly of the bonnet and the inner parts (Fig.: Art. EB310064)
5.4.2.2 Welding the body between pipes
The safety demands be welding are depending on the place and the position of the point of weld.
Welding the parts in a serviceable device/machine/plant the potential of danger is as higher as
If appropriate inform the shift foreman / safety engineer or the works manager and the fire brigade
of your factory.
By welding observe your own national guide lines about safety and the prevention of accidents.
o.k.
flow direction
Fig. 5.4 - non-return valves, swing-check valves, welding of the body (Fig.: body of Art. EB310064)
5.4.2.3 Mounting of the bonnet and the inner parts
Before mounting the bonnet and the inner parts let the body cool down.
Insert the inner parts and the spring into the body. Take care about the correct placement of the
inner parts and the spring.
Screw the bonnet into the body. Check the correct position of the sealing at the bonnet and take
care that there will be no pollution on the sealing or on the seat.
Tighten the bonnet with a fit spanner.
cool down
o.k.
Fig. 5.5 - non-return valve, swing-check valve, mounting of the bonnet and the inner parts (Fig.: Art. EB310064)
5.4.3 Mounting of the valve with flanged connection
and the valve (welded flanges) and they are cooled down..
Push the valve between the flanges by using the appropriate sealings. This process must happen
easily to avoid the damage of the sealings.
Align the borings of the flanges and put some fit screws through the holes. Screw the fit nuts onto
the screws and tighten them up crosswise.
Fasten all screws crosswise and check the function of the valve. Observe the maximum torque of
the screws.
o.k.
flow direction
Fig. 5.6 - non-return valves, swing-check valve, mounting with flanged connection (Fig.: Art. KU3000xx)
5.5 Maintenance
Before you maintain or shut down a non-return valve / swing-check valve you have to read the
Safety advice
to this page.
Non-return valves need on maintainance
If you determinate that there is a demage to the valve switch off the device/ machine/ plant!
However before doing this, it is essential to refer to the
Safety advice.
Notizen
(2) as defined by Pressure-Equipment-Directive 97/23/EG
AA, AB, AC, AD, AG, AK, AR, BE, BF, BG, BH, BK, CA, CB, CD, CK, CU, CV, CW, DK, EA, EA, EB, EK, FG,
HK, IC, IG, IK, IL, KA, KU, MA, MB, MD, MR, NG, NK, PB, PD, RG, RK, RM, SD, SK, SV, TA, TB, TC, TD,
TE, TF, TH, TR, UV, VA, VC, VD, VH, VK, VL, VM, VN, VO, VS, VT, VU, WG, ZA, ZD, ZE, ZF, ZG, ZK, ZP,
ZR, SONV, and all variations of these articles

Germany
(7) Notified body for conformity assessment PED an Quality-Management-System:
Bureau Veritas S.A.

Paris / Frankreich
Kennzeichen 0062

(9) On behalf Bad Oeynhausen, 20. Juli 2004


RK... D Betriebsanleitung
Rückschlagventile RK
 Installation Instructions
808519-07 Non-Return Valves RK
F Instructions de montage et de mise en service
Clapets de retenue RK
E Instrucciones de montaje y servicio
Válvulas de retención RK
I Manuale di Istruzioni
Valvole di non ritorno RK
 Инструкция по эксплуатации
Обратные клапаны RK
 Gebruiksaanwijzing
Terugslagkleppen RK
Sicherheitshinweis D
Das Gerät darf nur von geeigneten und unterwiesenen Personen montiert und in Betrieb
genommen werden. Wartungs- und Umrüstarbeiten dürfen nur von beauftragten
Beschäftigten vorgenommen werden, die eine spezielle Unterweisung erhalten haben.
Bestimmungsgemäßer Gebrauch D
Einsatz in Rohrleitungen zum Verhindern des Rückfließens von Medien innerhalb der
zulässigen Druck- und Temperaturgrenzen unter Beachtung der chemischen und
korrosiven Einflüsse auf das Druckgerät.
Die Medienbeständigkeit der Armatur muss für die Einsatzbedingungen geprüft werden.
Achtung D
Das Typenschild kennzeichnet die technischen Eigenschaften des Gerätes.
Ein Gerät ohne gerätespezifisches Typenschild darf nicht in Betrieb
genommen oder betrieben werden!
Gefahr D
Die Armatur steht während des Betriebs unter Druck!
Wenn Flanschverbindungen oder Verschlussschrauben gelöst werden,
strömen heißes Wasser, Dampf, ätzende Flüssigkeiten oder toxische Gase
aus. Schwere Verbrühungen und Verbrennungen am ganzen Körper sind
möglich! Schwere Vergiftungen sind möglich!
Montage- oder Wartungsarbeiten nur in drucklosem Zustand durchführen!
Die Armatur ist während des Betriebs heiß oder tiefkalt!
Schwere Verbrennungen an Händen und Armen sind möglich.
Montage- oder Wartungsarbeiten nur bei Raumtemperatur durchführen!
Scharfkantige Innenteile können Schnittverletzungen an den Händen
verursachen!
Beim Wechseln der Armatur Arbeitshandschuhe tragen!
ATEX (Atmosphère Explosible) D

Die Geräte weisen keine potenzielle Zündquelle auf und fallen daher nicht unter die
Explosionsschutz-Richtlinie 94/9/EG.
Einsetzbar in Ex-Zonen 0, 1, 2, 20, 21, 22 (1999/92/EG).
Die Geräte erhalten keine Ex-Kennzeichnung.
Technische Daten D
Einsatzgrenzen siehe Kennzeichnung bzw. Typenschildangaben (Druckklasse PN/Class,
Werkstoffnummer, Aufkleber für Weichdichtung, Federwerkstoff).
Reduzierte Temperaturgrenzen bei Verwendung von elastischen Dichtungen und bei
einigen Federwerkstoffen beachten.
Type PN / CL DN PMA / TMA [bar] / [°C]
RK 70 6 /- 15 - 100 6 / -30 0,5 / 130
RK 70 6 /- 125 - 200 6 / -10 0,5 / 130
RK 71 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 125 - 200 16 / -10 13 / 300
RK 44 16 /- 15 - 100 16 / -200 13 / 250
RK 44 16 /- 125 - 200 16 / -10 13 / 250
RK 44S 16 /- 15 - 100 16 / -200 16 / 90
RK 76 40 / 300 15 - 100 49,6 / -10 31,6 / 300
RK 86 40 / 300 15 - 100 51 / -10 36,9 / 350
RK 86 40 / 300 125 - 200 51 / -10 34,5 / 400
RK 86A 40 / 300 15 - 200 49,6 / -200 24 / 550
Technische Daten Fortsetzung D
RK 16A 40 / 300 15 - 100 49,6 / -200 24 / 550
RK 16C 40 / 300 15 - 100 49,6 / -200 29,3 / 400
RK 26A 40 / 300 15 - 100 49,6 / -200 25 / 550
RK 49 160 / – 15 - 65 160 / -10 110,8 / 550
RK 49 160 / – 80 - 200 160 / -10 55,3 / 530
RK 29A 63 / – 15 - 200 63 / -200 44,2 / 500
RK 29A 100 / – 15 - 200 100 / -200 70,2 / 500
RK 29A 160 / – 15 - 200 160 / -200 112,4 / 500
RK 29A 250 / – 15 - 200 250 / -200 175,6 / 500
RK 29A 320 / – 15 - 200 320 / -200 224,7 / 500
RK 29A 400 / – 15 - 200 400 / -200 280,9 / 500
RK 29A – / 400 15 - 200 66,2 / -200 37,6 / 500
RK 29A – / 600 15 - 200 99,3 / -200 56,6 / 500
RK 29A – / 900 15 - 200 148,9 / -200 84,7 / 500
RK 29A – / 1500 15 - 200 248,2 / -200 140,9 / 500
RK 29A – / 2500 15 - 200 413,7 / -200 235 / 500
Systembeschreibung D
Rückschlagventile RK mit Spiralring-Zentrierung oder Gehäuse-Zentrierung. Für Ventile
mit Schließfeder ist die Einbaulage beliebig. Ventile ohne Schließfeder nur in vertikale
Leitungen mit Strömungsrichtung von unten nach oben montieren.
1 Rückschlagventile mit Spiral-Zentrierung
2 Rückschlagventile mit Gehäuse-Zentriernocken
3 Rückschlagventile mit Gehäuse-Zentrierung
4 Position der Führungsleisten in horizontaler Leitung
Einbau D
TOP
1 2 3 4
Typenschild / Kennzeichnung D
Typ: RK ...
DN:... Typ: RK ...
PN:... DN:...
.......... PN:...
..........
Typ: RK ... Typ: RK ...

DN:... DN:...
PN:... PN:...
.......... ..........
1/02  2002
1  2002
02
Konformitätserklärung D
Für die Geräte RK... erklären wir die Konformität mit folgender europäischer Richtlinie:
 Druckgeräte-Richtlinie 97/23/EG vom 29.05.1997, soweit die Geräte nicht unter die
Ausnahmeregel nach Artikel 3.3 fallen.
 Angewandtes Konformitätsbewertungsverfahren: Anhang III, Modul H, überprüft
durch die benannte Stelle 0525.
Bei einer nicht mit uns abgestimmten Änderung des Gerätes verliert diese Erklärung ihre
Gültigkeit.
Bremen, den 11. 02.2005
GESTRA AG
Dipl.-Ing. Uwe Bledschun Dipl.-Ing. Lars Bohl

Leiter Konstruktion Qualitätsbeauftragter
Safety Note 
The equipment must only be installed and commissioned by qualified and adequately
trained personnel. Maintenance and retrofitting must only be performed by entrusted
personnel who – through adequate training – have achieved a recognized level of
competence.
Usage for the intended purpose 

The non-return valves RK are automatic-stop check valves and designed for use in
pipes in order to prevent the backflow of fluid. The admissible pressure and temperature
ratings as well as the chemical and corrosive influences of the fluid on the pressure
equipment must be taken into account. Check the chemical resistance and suitability of
the valve for the operating conditions in question.
Attention 
The name plate specifies the technical characteristics of the equipment.
Do not commission or operate a device without a name plate!
Danger 
The valve is under pressure during operation.
When loosening flanged connections or sealing plugs, hot water, steam,
corrosive fluids or toxic gases may escape. This presents the risk of severe
burns and scalds to the whole body or severe cases or poisoning.
Installation and maintenance work should only be carried out when the
system is depressurized.
The valve becomes hot or extremely cold during operation. This presents
the risk of severe burns to hands and arms. Installation and maintenance
work should only be carried out at room temperatures.
Sharp edges on internals present a danger of cuts to hands. Always wear
industrial gloves for installation and maintenance work.
ATEX Directive 94/9/EC, 1999/92/EC 

The equipment does not have its own potential source of ignition and is therefore not
subject to the Directive 94/9/EC.
The equipment can be used in the following explosive zones: 0, 1, 2, 20, 21 and 22.
The equipment does not require an Ex marking.
Technical Data 
For pressure ratings see marking or name plate (pressure class PN/Class, material
number, sticker for soft seal, spring material)
Observe lower temperature ratings for equipment with elastic seals and certain spring
materials.
Typ PN / CL DN PMA / TMA [bar] / [°C]

RK 70 6 /- 15 - 100 6 / -30 0.5 / 130
RK 70 6 /- 125 - 200 6 / -10 0.5 / 130
RK 71 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 125 - 200 16 / -10 13 / 300
RK 44 16 /- 15 - 100 16 / -200 13 / 250
RK 44 16 /- 125 - 200 16 / -10 13 / 250
RK 44S 16 /- 15 - 100 16 / -200 16 / 90
RK 76 40 / 300 15 - 100 49.6 / -10 31.6 / 300
RK 86 40 / 300 15 - 100 51 / -10 36.9 / 350
RK 86 40 / 300 125 - 200 51 / -10 34.5 / 400
RK 86A 40 / 300 15 - 200 49.6 / -200 24 / 550
Technical Data – continued – 
Typ PN / CL DN PMA / TMA [bar] / [°C]
RK 16A 40 / 300 15 - 100 49.6 / -200 24 / 550
RK 16C 40 / 300 15 - 100 49.6 / -200 29.3 / 400
RK 26A 40 / 300 15 - 100 49.6 / -200 25 / 550
RK 49 160 / – 15 - 65 160 / -10 110.8 / 550
RK 49 160 / – 80 - 200 160 / -10 55.3 / 530
RK 29A 63 / – 15 - 200 63 / -200 44.2 / 500
RK 29A 100 / – 15 - 200 100 / -200 70.2 / 500
RK 29A 160 / – 15 - 200 160 / -200 112.4 / 500
RK 29A 250 / – 15 - 200 250 / -200 175.6 / 500
RK 29A 320 / – 15 - 200 320 / -200 224.7 / 500
RK 29A 400 / – 15 - 200 400 / -200 280.9 / 500
RK 29A – / 400 15 - 200 66.2 / -200 37.6 / 500
RK 29A – / 600 15 - 200 99.3 / -200 56.6 / 500
RK 29A – / 900 15 - 200 148.9 / -200 84.7 / 500
RK 29A – / 1500 15 - 200 248.2 / -200 140.9 / 500
RK 29A – / 2500 15 - 200 413.7 / -200 235 / 500
Description 
Non-return valve RK with spiral centering ring or self-centering body. Installation in any
position. Exception: Valves without spring can only be installed in vertical lines with
upward flow.
1 Non-return valve with spiral centering ring
2 Non-return valve with body centering cams
3 Non-return valve with self-centering body
4 Position of guide ribs (horizontal installation)
Installation 
TOP
1 2 3 4
Name Plate / Marking 
Type: RK ...
DN:... Type: RK ...
PN:... DN:...
.......... PN:...
..........
Type: RK ... Type: RK ...

DN:... DN:...
PN:... PN:...
.......... ..........
1/02  2002
1  2002
02
Declaration of Conformity 
We hereby declare that the pressure equipment RK... conforms to the following European
Directive:
n Pressure Equipment Directive (PED) 97/23/EC of 29 May 1997 (except for equipment
excluded from the scope of the PED according to section 3.3).
n Applied conformity assessment procedure: Annex III, Module H, verified by the
Notified Body 0525.
This declaration is no longer valid if modifications are made to the equipment without
consultation with us.
Bremen, 11th February 2005
GESTRA AG
Head of the Design Dept. Quality Assurance Manager

Uwe Bledschun Lars Bohl
(Academically qualified engineer) (Academically qualified engineer)
Avis important pour la sécurité F
L’installation, la mise en service, l’entretien et les travaux de modification ne doivent être
realisés que par du personnel qualifié.
Utilisation conforme F
Le clapet de retenue s’utilise sur la tuyauterie pour éviter le reflux des fluides dans les
limites de pression et température admissibles.
Il est nécessaire de vérifier la compatibilité entre le fluide et les matériaux consituant le
clapet pour en assurer la longévité.
Attention F
La plaque d’identification indique les propriétés techniques de
l’appareil. Un appareil sans plaque d’identification spécifique ne doit
pas être mis en service ou exploité!
Danger F
En service le clapet de retenue est sous pression.
Lors du desserrage des brides ou des bouchons, de l’eau bouillante, de la
vapeur, des liquides ou gaz corrosifs ou toxiques peuvent s’échapper.
Il y a risque d’empoisonnement et de brûlures graves sur tout le corps.
Avant d’effectuer des travaux d’installation ou d’entretien, décomprimer
l’installation.
Pendant le fonctionnement de l’installation le clapet de retenue est très
chaud ou très froid.
Il y a risque de brûlures aux mains et aux bras. Avant d’effectuer des
travaux d’installation ou d’entretien vérifier que le purgeur est à
température ambiante.
Les pièces intérieures à arêtes vives peuvent causer des coupures aux
mains. Porter des gants de travail pour remplacer les pièces internes.
Directive ATEX 94/9/CE, 1999/92/CE F

Les équipements ne disposent pas de leur propre source potentielle d’inflammation,
par conséquent ils ne sont pas concernés par la directive 94/9/CE.
Les appareils peuvent être utilisés pour des zones explosibles 0, 1, 2, 20, 21 et 22.
Les équipements ne portent pas le marquage Ex.
Données techniques F
Plage d’utilisation – voir plaque d’identification ou marque (classe de pression PN/Class,
nuance matériaux, nuance joint souple et ressort).
Observer les restrictions (réduction des limites de température) pour des appareils avec
des joints élastiques ou certains matériaux de ressort.

RK 70 6 /- 15 - 100 6 / -30 0,5 / 130
RK 70 6 /- 125 - 200 6 / -10 0,5 / 130
RK 71 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 125 - 200 16 / -10 13 / 300
RK 44 16 /- 15 - 100 16 / -200 13 / 250
RK 44 16 /- 125 - 200 16 / -10 13 / 250
RK 44S 16 /- 15 - 100 16 / -200 16 / 90
RK 76 40 / 300 15 - 100 49,6 / -10 31,6 / 300
RK 86 40 / 300 15 - 100 51 / -10 36,9 / 350
RK 86 40 / 300 125 - 200 51 / -10 34,5 / 400
RK 86A 40 / 300 15 - 200 49,6 / -200 24 / 550
Données techniques – suite – F
RK 16A 40 / 300 15 - 100 49,6 / -200 24 / 550
RK 16C 40 / 300 15 - 100 49,6 / -200 29,3 / 400
RK 26A 40 / 300 15 - 100 49,6 / -200 25 / 550
RK 49 160 / – 15 - 65 160 / -10 110,8 / 550
RK 49 160 / – 80 - 200 160 / -10 55,3 / 530
RK 29A 63 / – 15 - 200 63 / -200 44,2 / 500
RK 29A 100 / – 15 - 200 100 / -200 70,2 / 500
RK 29A 160 / – 15 - 200 160 / -200 112,4 / 500
RK 29A 250 / – 15 - 200 250 / -200 175,6 / 500
RK 29A 320 / – 15 - 200 320 / -200 224,7 / 500
RK 29A 400 / – 15 - 200 400 / -200 280,9 / 500
RK 29A – / 400 15 - 200 66,2 / -200 37,6 / 500
RK 29A – / 600 15 - 200 99,3 / -200 56,6 / 500
RK 29A – / 900 15 - 200 148,9 / -200 84,7 / 500
RK 29A – / 1500 15 - 200 248,2 / -200 140,9 / 500
RK 29A – / 2500 15 - 200 413,7 / -200 235 / 500
Déscription F
Clapets de retenue RK avec bague de centrage spécial ou avec corps autorisant le
centrage. Montage en toutes positions, à la seule exception des clapets sans ressort de
rappel. Pour ces clapets, montage uniquement sur tuyauterie verticale, avec sens de
passage de bas en haut.
1 Clapet de retenue avec bague de centrage spéciale
2 Clapet de retenue avec butées autorisant le centrage
3 Clapet de retenue avec corps autorisant le centrage
4 Position des nervures de guidage (installation horizontale)
Installation F
TOP
1 2 3 4
Plaque d’identification / Marquage F
Type: RK ...
DN:... Type: RK ...
PN:... DN:...
.......... PN:...
..........
Type: RK ... Type: RK ...

DN:... DN:...
PN:... PN:...
.......... ..........
1/02  2002
1  2002
02
Déclaration de conformité F
Nous déclarons la conformité des appareils soumis à pression RK... avec la
Directive Européene suivante:
 Directive Equipements Soumis à Pression (DESP) 97/23/EC du 29 mai 1997
(sauf les cas d’exclusion suivant l’article 3.3).
 Procédure d’évaluation de la conformité appliquée : annexe III, module H, vérifié
par l’organisme notifié 0525.
Cette déclaration n’est plus valable si une modification est apportée à l’appareil
sans notre accord.
Brême, le 11 février 2005
GESTRA AG

Directeur de la conception Délégué à la qualité
Advertencia sobre seguridad E
El equipo sólo debe ser instalado y puesto en marcha por personal cualificado y
especializado. Los trabajos de mantenimiento, sustitución o reparación sólo deben ser
realizados por personal que dispone de una formación especial.
Aplicación de acuerdo con la finalidad E

Las válvulas de retención se utilizan en tuberías para limitar el paso del fluido en
un solo sentido dentro de las temperaturas y presiones especificadas. Debido a la
influencia química y corrosiva del fluido sobre la resistencia de la válvula recomendamos
comprobar la idoneidad del material de la válvula para la aplicación en cuestión.
Atención E
En la placa de características están especificadas las propiedades técnicas
del aparato. ¡Nunca poner en operación ni trabajar con un aparato que
carezca de la placa de características especifica del aparato!
Peligro E
La válvula está sometida a presión durante el funcionamiento. Al aflojar los
tornillos de las bridas o los tapones de cierre podría producirse escape de
agua caliente, vapor, líquidos corrosivos o gases tóxicos. Existe el peligro de
sufrir graves quemaduras, heridas o intoxicaciones por inhalación cuando se
produzca un escape de fluido. Los trabajos de montaje o mantenimiento sólo
deben ser realizados cuando la válvula no se encuentre sometida a presión.
Dado que en operación la válvula puede encontrarse a temperatura muy
elevada o muy baja, existe el peligro de sufrir importantes quemaduras en
las manos y brazos si se manipula sin precaución. Los trabajos de montaje o
mantenimiento deberán realizarse únicamente a temperatura ambiente. Las
partes internas por tener terminaciones afiladas, pueden ocasionar heridas
cortantes en las manos. Utilizar siempre guantes de trabajo para realizar los
trabajos de montaje o de mantenimiento.
Directiva ATEX 94/9/EC 1999/92/EC E

Los equipos no tienen fuentes potenciales de ignición y por eso no entran en el ámbito
de aplicación la directiva 94/9/EC.
Los equipos se pueden usar en las zonas explosivas 0, 1, 2, 20, 21 y 22.
Los equipos no requieren un marcado Ex.
Datos técnicos E
Margen de aplicación – véase marcaje o placa característica (clase de presión PN/Class,
número de material, etiqueta para junta blanda, material de resorte). Tener en cuenta las
restricciones (reducción de temperatura para los aparatos con juntas blandas o para
unos materiales de resorte.
Tipo PN / CL DN PMA / TMA [bar] / [°C]

RK 70 6 /- 15 - 100 6 / -30 0,5 / 130
RK 70 6 /- 125 - 200 6 / -10 0,5 / 130
RK 71 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 125 - 200 16 / -10 13 / 300
RK 44 16 /- 15 - 100 16 / -200 13 / 250
RK 44 16 /- 125 - 200 16 / -10 13 / 250
RK 44S 16 /- 15 - 100 16 / -200 16 / 90
RK 76 40 / 300 15 - 100 49,6 / -10 31,6 / 300
RK 86 40 / 300 15 - 100 51 / -10 36,9 / 350
RK 86 40 / 300 125 - 200 51 / -10 34,5 / 400
RK 86A 40 / 300 15 - 200 49,6 / -200 24 / 550
Datos técnicos – continuación – E
RK 16A 40 / 300 15 - 100 49,6 / -200 24 / 550
RK 16C 40 / 300 15 - 100 49,6 / -200 29,3 / 400
RK 26A 40 / 300 15 - 100 49,6 / -200 25 / 550
RK 49 160 / – 15 - 65 160 / -10 110,8 / 550
RK 49 160 / – 80 - 200 160 / -10 55,3 / 530
RK 29A 63 / – 15 - 200 63 / -200 44,2 / 500
RK 29A 100 / – 15 - 200 100 / -200 70,2 / 500
RK 29A 160 / – 15 - 200 160 / -200 112,4 / 500
RK 29A 250 / – 15 - 200 250 / -200 175,6 / 500
RK 29A 320 / – 15 - 200 320 / -200 224,7 / 500
RK 29A 400 / – 15 - 200 400 / -200 280,9 / 500
RK 29A – / 400 15 - 200 66,2 / -200 37,6 / 500
RK 29A – / 600 15 - 200 99,3 / -200 56,6 / 500
RK 29A – / 900 15 - 200 148,9 / -200 84,7 / 500
RK 29A – / 1500 15 - 200 248,2 / -200 140,9 / 500
RK 29A – / 2500 15 - 200 413,7 / -200 235 / 500
Descripción E
Válvulas de retención RK con anillo de centraje espiral o con cuerpo de centraje.
Instalación en cualquier posición. Excepción: Válvulas sin muelles sólo se deben
instalar en tuberías verticales con flujo ascendente.
1 Válvula de retención con anillo de centraje espiral
2 Válvula de retención con topes de centraje
3 Válvula de retención con cuerpo de centraje
4 Posición de los nervios guía en caso de instalación horizontal
Montaje E
TOP
1 2 3 4
Placa característica / Marcaje E
Tipo: RK ...
DN:... Tipo: RK ...
PN:... DN:...
.......... PN:...
..........
Tipo: RK ... Tipo: RK ...

DN:... DN:...
PN:... PN:...
.......... ..........
1/02  2002
1  2002
02
Declaración de conformidad E
Declaramos que los equipos de presión RK... cumplen con la directiva europea siguiente:
n Directiva de Equipos a Presión (DEP) 97/23/CE del 29 mayo 1997 (excepto los casos
de exclusión según el párrafo 3.3 de la Directiva).
n Procedimiento de evaluación de conformidad aplicado: anexo III, módulo H,
verificado por el organismo notificado 0525.
Esta declaración pierde su validez en el caso de que se realicen modificaciones en
los equipos que no hayan sido acordadas con nosotros.
Bremen, 11. 02. 2005
GESTRA AG
Uwe Bledschun Lars Bohl

Director de Diseño Encargado de Calidad
Note di sicurezza I
Le valvole devono essere installate e poste in esercizio solo da personale qualificato
ed adeguatamente istruito. La manutenzione ed eventuali sostituzioni devono essere
eseguite solo da personale che, dopo adeguati training, possegga un riconosciuto livello
di competenze.
Uso appropriato I
Le valvole RK sono valvole automatiche progettate per essere utilizzate su tubazioni per
bloccarne il flusso di ritorno. Devono essere tenuti in considerazione sia i limiti di
Pressione/Temperatura che gli effetti chimici e di corrosione del fluido utilizzato.
Verificare scrupolosamente la resistenza alle aggressioni chimiche nelle effettive
condizioni di esercizio.
Attenzione I
La targhetta indica i dati tecnici dello scaricatore.
Non montare scaricatori privi di targhetta dati.
Pericolo I
Durante l’esercizio la valvola è sotto pressione.
Smontando la valvola o allentando le viti acqua calda, vapore, fluidi
corrosivi o gas tossici potranno fuoriuscire violentemente. Ciò provocherà
scottature su tutto il corpo e/o casi gravi di avvelenamento.
Questi lavori devono essere sempre eseguiti ad impianto freddo e senza
pressione.
Le valvole, durante l’esercizio, possono essere estremamente calde o
fredde e quindi provocare seri danni a mani e braccia. L’installazione e la
manutenzione devono essere sempre eseguite a temperatura ambiente.
Parti interne con spigoli vivi possono causare lesioni alle mani, per questo
motivo raccomandiamo l’uso di robusti guanti da lavoro.
Direttiva ATEX 94/9//EC, 1999/92/EC I

La valvola non ha una propria sorgente di innesco e non è perciò soggetta alla
Direttiva 94/9/EC.
La valvola può essere impiegata nelle seguenti zone pericolose: 0, 1, 2, 20, 21 e 22.
La valvola non necessita di marchio Ex.
Dati tecnici I
I dati di rating Pressione possono essere rilevati sulla targhetta dati (classe di pressione
PN/Class, codice materiale del corpo e della molla, materiale della eventuale sede
soffice). Verificare accuratamente, nel caso di basse temperature e tenuta soffice, il
rating della valvola e la compatibilità di alcuni tipi di molle.

RK 70 6 /- 15 - 100 6 / -30 0,5 / 130
RK 70 6 /- 125 - 200 6 / -10 0,5 / 130
RK 71 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 125 - 200 16 / -10 13 / 300
RK 44 16 /- 15 - 100 16 / -200 13 / 250
RK 44 16 /- 125 - 200 16 / -10 13 / 250
RK 44S 16 /- 15 - 100 16 / -200 16 / 90
RK 76 40 / 300 15 - 100 49,6 / -10 31,6 / 300
RK 86 40 / 300 15 - 100 51 / -10 36,9 / 350
RK 86 40 / 300 125 - 200 51 / -10 34,5 / 400
RK 86A 40 / 300 15 - 200 49,6 / -200 24 / 550
Dati tecnici – continua – I
RK 16A 40 / 300 15 - 100 49,6 / -200 24 / 550
RK 16C 40 / 300 15 - 100 49,6 / -200 29,3 / 400
RK 26A 40 / 300 15 - 100 49,6 / -200 25 / 550
RK 49 160 / – 15 - 65 160 / -10 110,8 / 550
RK 49 160 / – 80 - 200 160 / -10 55,3 / 530
RK 29A 63 / – 15 - 200 63 / -200 44,2 / 500
RK 29A 100 / – 15 - 200 100 / -200 70,2 / 500
RK 29A 160 / – 15 - 200 160 / -200 112,4 / 500
RK 29A 250 / – 15 - 200 250 / -200 175,6 / 500
RK 29A 320 / – 15 - 200 320 / -200 224,7 / 500
RK 29A 400 / – 15 - 200 400 / -200 280,9 / 500
RK 29A – / 400 15 - 200 66,2 / -200 37,6 / 500
RK 29A – / 600 15 - 200 99,3 / -200 56,6 / 500
RK 29A – / 900 15 - 200 148,9 / -200 84,7 / 500
RK 29A – / 1500 15 - 200 248,2 / -200 140,9 / 500
RK 29A – / 2500 15 - 200 413,7 / -200 235 / 500
Descrizione I
Le valvole RK con dispositivo di centraggio a filo o con corpo sagomato possono essere
installate in qualsiasi posizione. Nel caso di valvole senza molla, queste dovranno
essere montate su linee verticali con flusso dal basso verso l’alto.
1 Valvola di non ritorno con anello di centraggio a filo
2 Valvola di non ritorno con corpo autocentrante a camme
3 Valvola di non ritorno con corpo autocentrante
4 Posizione nervature di guida (installazione orizzontale)
Installazione I
ALTO
1 2 3 4
Targhetta dati / Marcature I
Tipo: RK ...
DN:... Tipo: RK ...
PN:... DN:...
.......... PN:...
..........
Tipo: RK ... Tipo: RK ...

DN:... DN:...
PN:... PN:...
.......... ..........
1/02  2002
1  2002
02
Dichiarazione di compatibilità I
Con la presente dichiariamo che le valvole RK..., sono conformi alla direttiva europea
seguente:
 Pressure Equipment Directive (PED) No. 97/23/CE del 29 maggio 1997 (tranne quelle
escluso dalla sezione 3.3 della PED).
 Le applicazioni delle procedure di conformità: Allegato III; Modulo H, sono eseguite
dall’ Organismo Notificato 0525.
In caso di modifiche non con noi concordate questa dichiarazione perde ogni sua
validità.
Brema, 11 febbraio 2005
GESTRA AG

Coordinatore Costruzione Responsabile Qualità
Указание по безопасности 
Монтаж и ввод оборудования в эксплуатацию разрешается производить только силами
квалифицированного и проинструктированного соответствующим образом персонала.
Техническое обслуживание и замена оборудования должны осуществляться только
персоналом, специально назначенным для проведения данных работ и прошедшим
соответствующий инструктаж.
Использование по назначению 
Обратные клапаны RK применяются в трубопроводах для предотвращения движения потока
среды в обратном направлении. При выборе борудования необходимо принимать во внимание
диапазон допустимых давлений и температур, учитывать химическую и коррозионную
стойкость борудования, находящегося под давлением, к используемой среде. Проверяйте
химическую стойкость материалов, из которых изготовлено оборудование, и пригодность
оборудования для эксплуатации в конкретных рабочих условиях.
Внимание 
На фирменной табличке указаны технические характеристики оборудования.
Если на оборудовании нет фирменной таблички, то это оборудование не
должно устанавливаться и эксплуатироваться.
Предупреждение об опасности 
В рабочем режиме оборудование находится под давлением! При откручивании
соединительных фланцев или уплотнительных пробок может вытекать горячая
вода, агрессивная жидкость, выходить токсичный газ или пар. Возможно получение
тяжелых ожогов всего тела или отравлений! Монтаж и техническое обслуживание
оборудования должны производиться только при нулевом избыточном давлении
в трубопроводе перед и после оборудования. Во время работы оборудование
становится горячим или сильно холодным. Возможно получение тяжелых ожогов
кистей рук и предплечий. Монтаж и техническое обслуживание оборудования
следует проводить только при комнатной температуре. Внутренние части
оборудования имеют острые края, которыми можно порезаться. Монтаж и
техническое обслуживание необходимо проводить всегда в рабочих перчатках.
Директива ATEX (Atmosphère Explosible) 94/9/EC, 1999/92/EC 

Данное оборудование может применяться в следующих взрывоопасных зонах: 0, 1, 2, 20, 21
и 22. Данное оборудование не является потенциально взрывоопасным и, соответственно, не
подпадает под действие Директивы 94/9/EC. Данное оборудование не требует маркировки Ex
(взрывобезопасное исполнение). Поверхность оборудования не нагревается до чрезмерно высоких
температур. Обслуживающий персонал должен убедиться в том, что рабочая среда не нагревает
поверхность оборудования до недопустимо высоких температур.
Технические характеристики 
Для определения характеристик клапана по давлению смотри маркировку на корпусе
или фирменную табличку (класс давления PN/Class, код материала, материал пружины,
наклейка на корпусе при использовании мягкого уплотнения).
Уточняйте минимально допустимую температуру для клапанов с мягкими уплотнениями и
определенными материалами пружин.
Тип PN / CL DN Макс. раб. давл. / Макс. раб. темп. [бар] / [°C]
RK 70 6 /- 15 - 100 6 / -30 0,5 / 130
RK 70 6 /- 125 - 200 6 / -10 0,5 / 130
RK 71 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 125 - 200 16 / -10 13 / 300
RK 44 16 /- 15 - 100 16 / -200 13 / 250
RK 44 16 /- 125 - 200 16 / -10 13 / 250
RK 44S 16 /- 15 - 100 16 / -200 16 / 90
RK 76 40 / 300 15 - 100 49,6 / -10 31,6 / 300
RK 86 40 / 300 15 - 100 51 / -10 36,9 / 350
RK 86 40 / 300 125 - 200 51 / -10 34,5 / 400
RK 86A 40 / 300 15 - 200 49,6 / -200 24 / 550
Технические характеристики 
Тип PN / CL DN Макс. раб. давл. / Макс. раб. темп. [бар] / [°C]
RK 16A 40 / 300 15 - 100 49,6 / -200 24 / 550
RK 16C 40 / 300 15 - 100 49,6 / -200 29,3 / 400
RK 26A 40 / 300 15 - 100 49,6 / -200 25 / 550
RK 49 160 / – 15 - 65 160 / -10 110,8 / 550
RK 49 160 / – 80 - 200 160 / -10 55,3 / 530
RK 29A 63 / – 15 - 200 63 / -200 44,2 / 500
RK 29A 100 / – 15 - 200 100 / -200 70,2 / 500
RK 29A 160 / – 15 - 200 160 / -200 112,4 / 500
RK 29A 250 / – 15 - 200 250 / -200 175,6 / 500
RK 29A 320 / – 15 - 200 320 / -200 224,7 / 500
RK 29A 400 / – 15 - 200 400 / -200 280,9 / 500
RK 29A – / 400 15 - 200 66,2 / -200 37,6 / 500
RK 29A – / 600 15 - 200 99,3 / -200 56,6 / 500
RK 29A – / 900 15 - 200 148,9 / -200 84,7 / 500
RK 29A – / 1500 15 - 200 248,2 / -200 140,9 / 500
RK 29A – / 2500 15 - 200 413,7 / -200 235 / 500
Описание 
Обратный клапан RK с центрирующим спиральным кольцом или с
самоцентрирующимся корпусом. Клапан может быть смонтирован в любом положении.
Исключение: клапаны без пружины монтируются только в вертикальных
трубопроводах с направлением движения среды «снизу-вверх».
1 Обратный клапан с центрирующим спиральным кольцом
2 Обратный клапан с центрирующими приливами на корпусе
3 Обратный клапан с самоцентрирующимся корпусом
4 Расположение направляющих ребер (пи монтаже в горизонтальном
трубопроводе)
Монтаж 
ВЕРХ
1 2 3 4
Фирменная табличка/ Маркировка 
Typ: RK ...
DN:... Typ: RK ...
PN:... DN:...
.......... PN:...
..........

DN:... DN:...
PN:... PN:...
.......... ..........
1/02  2002
1  2002
02
Декларация соответствия 
Для устройств RK... мы заявляем о соответствии требованиям следующих
Европейских Директив:
n Директива Европейского Союза PED 97/23 (оборудование, работающее под
давлением) от 29.05.1997, если устройства не подпадают под исключительное
правило статьи 3.3.
n Примененный метод оценки соответствия: Приложение III, модуль H, проверено
названной лабораторией 0525.
Оборудование, соответствующее Директиве PED 97/23, маркируется CE 0525.
В случае несогласованного с нами изменения конструкции устройства данная
декларация теряет силу.
Бремен, 11.02.2005
GESTRA AG

(Дипл.-инж. Уве Бледшун) (Дипл.-инж. Ларс Боль)
Leiter Konstruktion Qualitätsbeauftragter
(Рук-ль конструкторского отдела) (Ответственный за качество)
Veiligheidsinstructie 
Het instrument mag alleen door geschikt en opgeleid personeel worden gemonteerd en
in bedrijf worden genomen.
Onderhouds- en ombouwwerkzaamheden mogen alleen door geautoriseerd personeel
worden uitgevoerd, die daarvoor speciaal zijn opgeleid.
Toepassing 
Toepassing in leidingen ter voorkoming van terugstromen van het medium binnen de
toelaatbare druk- en temperatuurgrenzen, rekening houdend met de chemische en
corrosieve invloeden op het drukapparaat.
De mediumbestendigheid van de armatuur moet voor de toepassingscondities
gecontroleerd worden.
Opgelet 
De typeplaat specificeert de technische eigenschappen van het apparaat.
Een apparaat zonder specifieke typeplaat mag niet in bedrijf worden
genomen of worden gebruikt.
Gevaar 
De armatuur staat tijdens bedrijf onder druk!
Wanneer flensverbindingen of dekselbouten los worden gedraaid, stromen
er heet water, stoom, etsende vloeistoffen of toxische gassen uit. Zware
verbrandingen over het gehele lichaam zijn mogelijk!
Zware vergiftigingen zijn mogelijk!
Montage- of onderhoudswerkzaamheden alleen in drukloze toestand
uitvoeren!
De armatuur is heet of zeer koud tijdens bedrijf!
Ernstige brandwonden aan handen en armen zijn mogelijk.
Montage- of onderhoudswerkzaamheden mogen uitsluitend bij kamertem-
peratuur worden uitgevoerd!
Scherpe inwendige onderdelen kunnen snijwonden aan de handen
veroorzaken!
Draag werkhandschoenen bij het vervangen van de armatuur!
ATEX (Atmospère Explosible) 

Apparaten hebben geen potentiële ontstekingsbron en vallen daarom niet onder de
explosieveiligheidsrichtlijn 94/9/EG. Toepasbaar in Ex-zone 0, 1, 2, 20, 21, 22
(1999/92/EG). Apparaten hebben geen Ex-markering.
Technische specificaties 
Voor drukgrenzen zie aanduiding op bijv. het typeplaatje (drukklasse PN/Class,
materiaalnummer, sticker voor zachte dichting, veermateriaal).
Er gelden lagere temperatuurgrenzen bij toepassing van elastische afdichtingen en
bepaalde veermaterialen.
RK 70 6 /- 15 - 100 6 / -30 0,5 / 130
RK 70 6 /- 125 - 200 6 / -10 0,5 / 130
RK 71 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 125 - 200 16 / -10 13 / 300
RK 44 16 /- 15 - 100 16 / -200 13 / 250
RK 44 16 /- 125 - 200 16 / -10 13 / 250
RK 44S 16 /- 15 - 100 16 / -200 16 / 90
RK 76 40 / 300 15 - 100 49,6 / -10 31,6 / 300
RK 86 40 / 300 15 - 100 51 / -10 36,9 / 350
RK 86 40 / 300 125 - 200 51 / -10 34,5 / 400
RK 86A 40 / 300 15 - 200 49,6 / -200 24 / 550
Technische specificaties 
RK 16A 40 / 300 15 - 100 49.6 / -200 24 / 550
RK 16C 40 / 300 15 - 100 49.6 / -200 29.3 / 400
RK 26A 40 / 300 15 - 100 49.6 / -200 25 / 550
RK 49 160 / – 15 - 65 160 / -10 110.8 / 550
RK 49 160 / – 80 - 200 160 / -10 55.3 / 530
RK 29A 63 / – 15 - 200 63 / -200 44.2 / 500
RK 29A 100 / – 15 - 200 100 / -200 70.2 / 500
RK 29A 160 / – 15 - 200 160 / -200 112.4 / 500
RK 29A 250 / – 15 - 200 250 / -200 175.6 / 500
RK 29A 320 / – 15 - 200 320 / -200 224.7 / 500
RK 29A 400 / – 15 - 200 400 / -200 280.9 / 500
RK 29A – / 400 15 - 200 66.2 / -200 37.6 / 500
RK 29A – / 600 15 - 200 99.3 / -200 56.6 / 500
RK 29A – / 900 15 - 200 148.9 / -200 84.7 / 500
RK 29A – / 1500 15 - 200 248.2 / -200 140.9 / 500
RK 29A – / 2500 15 - 200 413.7 / -200 235 / 500
Systeembeschrijving 
Terugslagkleppen RK met spiraalringcentrering of huiscentrering.
Inbouw in elke gewenste stand. Voor terugslagkleppen met sluitveer is de
inbouwpositie willekeurig. Terugslagkleppen zonder sluitveer alleen in verticale
leidingen met doorstroomrichting van onderen naar boven monteren.
1 Terugslagklep met spiraalring-centrering
2 Terugslagklep met huiscentreernok
3 Terugslagklep met huiscentrering
4 Positie geleidingsribben bij horizontale inbouw
Inbouw 
TOP
1 2 3 4
Typeplaat / identificatie 
Typ: RK ...
DN:... Typ: RK ...
PN:... DN:...
.......... PN:...
..........

DN:... DN:...
PN:... PN:...
.......... ..........
1/02  2002
1  2002
02
Conformiteitverklaring 
Voor de drukapparaten RK... verklaren wij de conformiteit met de volgende Europese
richtlijnen:
n Drukapparaat richtlijn 97/23/EG van 29.05.97, voor zover de apparaten niet onder
de uitzonderingsregel conform artikel 3.3 vallen.
 Gebruikte conformiteits-controlemethode: appendix III, module H, gecontroleerd
door geautoriseerd instituut 0525.
Bij een niet met ons afgestemde modificatie aan het apparaat verliest deze
verklaring haar geldigheid.
Bremen, 11. 02.2005

GESTRA AG

Leiter Konstuktion Qualitätsbeauftragter
GESTRA® www.gestra.de
E GESTRA ESPAÑOLA S.A  GESTRA Polonia Spolka z.o.o.

Luis Cabrera, 86-88 Ul. Schuberta 104
E-28002 Madrid PL - 80-172 Gdansk
Tel. 0034 91 / 5 15 20 32 Tel. 0048 58 / 3 06 10 - 02
Fax 0034 91 / 4 13 67 47, 5 15 20 36 0048 58 / 3 06 10 - 10
E-mail: aromero@flowserve.com Fax 0048 58 / 3 06 33 00
E-mail: gestra@gestra.pl
 Flowserve GB Limited
Abex Road Flowserve Portuguesa, Lda.
Newbury, Berkshire RG14 5EY
P Av. Dr. Antunes Guimarães, 1159
Tel. 0044 16 35 / 4 69 99 Porto 4100-082
Fax 0044 16 35 / 3 60 34 Tel. 00351 22 / 6 19 87 70
E-mail: gestraukinfo@flowserve.com Fax 00351 22 / 6 10 75 75
E-mail: jtavares@flowserve.com
I Flowserve S.p.A.
Flow Control Division  Flowserve GESTRA U.S.
Via Prealpi, 30 2341 Ampere Drive
l-20032 Cormano (MI) Louisville, KY 40299
Tel. 0039 02 / 66 32 51 Tel. 001 502 / 267-2205
Fax 0039 02 / 66 32 55 60 Fax 001 502 / 266-5397
E-mail: infoitaly@flowserve.com E-mail: FCD-Gestra-USA@flowserve.com
GESTRA® www.gestra.de
GESTRA AG
Postfach 10 54 60, D-28054 Bremen
Münchener Str. 77, D-28215 Bremen
Telefon 0049 (0) 421 / 35 03 - 0
Telefax 0049 (0) 421 / 35 03 - 393
E-Mail gestra.ag@flowserve.com
Internet www.gestra.de
808519-07/1106cs · 1999 GESTRA AG · Bremen · Printed in Germany

Globe valves,
Gate valves,
Needle valves
Operation and Installation Manual

Impressum
This documentation may neither be altered, expanded , reproduced nor passed to third parties without the
written agreement of END-Armaturen GmbH & Co. KG . This restriction also applies to the corresponding
drawings.
END-Armaturen GmbH & Co. KG has the right or change parts of the globe valves, gate valves, needle valves
at any time without prior or direct notice to the client. The contents of this publication are subject to change
without notice.
The products are specified by the statements in this documentation; no assurance or the properties is given.

Telefon: 05731 / 7901 - 0
Telefax: 05731 / 7901 - 98
E-Mail: post@end.de
Edition: 10/02
Contents
Inhalt
1 Foreword 4
2 General advice 5
2.1 Validity 5
2.3 Complaints 5
2.4 Guarantee 5
3 Safety advice 7
3.1. Personal protection 7
3.1.1. Safety advice for mounting 7
3.1.3 Satety advice for maintaining / repairing 8
3.2 Device Safety 9
4 Name-plate 10
5 Globe valves, Gate valves, Needle valves 11

5.1 General 11
5.3 Operation 11
5.4 Mounting / Disassembly 11
5.4.1 Mounting of the valve with threaded connection 12
5.4.2 Mounting of the valve with welded connection 12
5.4.2.1 Disassembly of the valve`s top 13
5.4.2.2 Mounting of the valve with welded connection 13
5.4.2.3 Mounting of the valve top 14
5.4.3 Mounting of the valve with flanged connection 15
5.5 Maintainance 16
5.5.1 Gland 16
Foreword
1 Foreword
Dear customer,
necessary for you to be able to carry out the mounting and adjustment of the valves rapaidly and
correctly.
notes.
Only instructed and qualified mechanician should mount, adjust or maintain the valves.
If you have any questions in relation to the globe valves, gate valves or the needle valves we shall
be pleased to answer them.
manual.
Yours
General advice
2 General advice
2.1 Validity
These mounting and installation manual is valid for the standard version of the valves.
Please check
• directly after delivery the valve for any transport damages and deficiencies.
• with reference to the accompanying delivery note the number of parts.
2.3 Complaints

2.4 Guarantee
For our globe valves, gate valves and needle valvess we give a guarantee period in accordance
with the sales contract.
Safety advice
3 Safety advice
Depending on the technical circumstances and the time under and at which the globe valve, gate
valve, needle valve is mounted, adjusted and commissioned, you must in each case take into
account particular safety aspects!
If, for example, the valve works in an operational chemical plant, the potential hazards of commis-
sioning have another dimension from that when this is only being carried out for test purposes an
a „dry“ part of the plant in the assembly room.
Since we do not know the circumstances at the time of the mounting / adjusting / commissioning
you may find advice on hazards in the following description which are not relevant to you.
Please observe (only) the advices wich applies to your situation!
3.1. Personal protection
3.1.1. Safety advice for mounting
We wish to point out expressly that the mounting, the electrical installation and the adjustment of
the globe valve, gate valve, needle valve and the accessories must be carried out only by trained
specialist personnel having mechanical and electrical knowledge!
At first switch off all the devices / machines / plant affected by mounting or repair!
will causes potential danger!
If appropriate, in the event of a fault in the globe valve, gate valve, needle valve (in a plant which
is in operation) inform the shift foreman / safety engineer or the works manager without delay
about the fault, in order, for example, to avoid an outflow / overflow of chemicals or the discharge
of gases in good time by means of suitable measures!
Before mounting or repair, remove the pressure from pneumatic / hydraulic devices / machines
/ plant!
Emty the conduit from medium.
machine / plant.
carrying out the mounting / repair.
Check the correct funtioning of the safety equipment (for example the emergency push off buttons
/safety valves, etc.!
As a result of the operation of a globe valve, gate valve or needle valve the flow of gases, steam,
liquids, etc. may be enabled or interrupted. Satisfy yourself that, as a result of the starting or the
test adjustment of the valve, no potential hazards for the personnel or the invironment will be
produced!
Safety advice
If necessary, set up warning signs in order to prevent the inadvertent starting or shutting down of
the devices / machine / plant.
By ending mounting check the correct function and the tightness of the globe valve / gate valve
/needle valve.
Through suitable meaures, prevent links being trapped by moving actuating elements.
valves, etc.)
this documentation.
3.1.3 Satety advice for maintaining / repairing
Never try to repair or maintain a globe valve, gate valve, needle valve under pressure.
Before disassembling the globe valve, gate valve, needle valve some essential points should be
clarified:
• Will the valve to be disassembled be replaced immediately by another?
• Could the valve remain in the pipe?
• If appropriate, does the production process of the plant need to be stopped?
• Is it necessary to inform specific personnel about the disassembly? etc.
If necessary, inform the shift foreman / safety engineer or the manager about the disturbance
without delay in order, for example, to avoid an outflow / overflow of chemicals or a discharge
of gases in good time by means of suitable measures!
Observe that some valves / armatures are able to enclose the pressured medium e.g. the ball
in the ball valve. You have to release the pressure in the pipes in which the armature / valve is
mounted.
If necessary, set up warning signs in order to prevent

- the inadvertent starting up of the devices / machines / plants, or
- the switching on of the medium.
In case of a defect in the globe valve, gate valve, needle valve make contact to the supplier. The
telephone number will be found on the back cover of these operation and installation manual.
If you determinate that there is a demage to the globe valve, gate valve, needle valve isolate it
from the device/ machine. However before doing this, it is essential to refer to the safety advice.
Don`t mount or start the globe valve, gate valve, needle valve or carry out any adjustments on it
if the globe valve, gate valve, needle valve, the supply lines or the part of the plant on which it is
mounted is damaged!
After a repair / maintenance check the right function of the globe valve, gate valve, needle valve
and the tightness of all connnections.
Safety advice
3.2 Device Safety
The globe valve, gate valve, needle valve

• is a quality product which is produced in accordance with the recognized industrial regulations.
• left the manufactuer`s work in a perfect condition!
with the descriptions in these instructions, technically correctly and with the greatest possible
precision!
We assume that you have, as a trained specialist, sound mechanical and electrical knowledge!
The globe valve, gate valve, needle valve must be used only for a purpose corresponding to its
construction!
The globe valve, gate valve, needle valve must be used within the values specified in the technical
data.
Operate the globe valve, gate valve, needle valve only inside the allowed temperature range.
Don`t operate the globe valve, gate valve, needle valve with a pressure as higher as the nominal
pressure.
Never remove the bonnet or other parts from the globe valve, gate valve, needle valve if it is under
pressure.
Don`t mount or start the globe valve, gate valve, needle valve or carry out any adjustments on it
if the globe valve, gate valve, needle valve the supply lines or the part of the plant on which it is
mounted is damaged!
By ending mounting check the correct function and the tightness of the globe valve, gate valve,
needle valve und check the correct function.
Name-plate
4 Name-plate
The globe valve, gate valve, needle valve will be provided with a name-plate, which permitts a definite identifi-
cation of the valves and shows the most important technical data to you. The name-plate should not displaced
or changed.
omation GmbH & Co. KG END-Armaturen GmbH & Co. KG

Bad Oeynhausen D-32547 Bad Oeynhausen
1 - 7901-0 www.end.de +49 (0)5731 - 7901-0
7900-0 www.end.de
22050 Art.Nr.:
Art. No.: ZA310028-ED620632
AE311028
Serie:
Serial: 313857
220885
: 8 bar Betriebsdruck
Pressure range(PS):
(PS): 16 16 barbar
6 bar Steuerdruck:
Pilot pressure: 6-8 - bar
bar
-30°C ... +180°C Temperatur
Temperature(TS): -30°C
range (TS): ... +180°C
-20°C ... +180°C
50 / G2" Größe (DN):
Size (DN): 50 / 50
G2"/ G2"
60 bar Prüfdruck (PT): (PT): 60 bar
Testing pressure 60 bar
1 Fluidgruppe:
Fluidgroup: 1 1
14.02.2002 Herstellung:
Date of manufacturing:13.11.2002
14.02.2002
0062
Fig. 4.1 - Name-plate
Art.No. article number of the valve

Serial order- or production-number
Pressure range (PS) max. admisable working pressure of the valve [bar]
Temperature (TS) temperature range of the valve
G / DN connecting size of the valve
Testing pressure (PT) testing pressure of body
Fluidgoup allowed fluid group of the valve
Date of manufacturing month and year of manufacturing
Globe valves, Gate valves, Needle valves
5 Globe valves, Gate valves, Needle valves
5.1 General
Before you mount /disassemble, adjust or commission a globe valve, gate valve, needle valve
you must have read the
Safety advice
If you have not read the safety advices until now please read these important advices now and
turn back to this point.
Globe valves. gate valves and needle valves will be used to cut off medium flow.
It should only be used clean liquids and gases, on which the material of the valves and the material
of the sealings will be resistant. Pollution or using outside the nominal pressure range and/or the
nominal temperature range should causes damages on the valves especially on the seals.
Metallic sealed valves should only be used for liquid media.
5.3 Operation
Globe valves, gate valves and needle valves should be actuated by turning a handwheel or a hand
knob.
By non totally opening / closing of the valve you will be able to control the media flow.
During the operation of the valve take care that there won`t be insert any objects or limbs into
the armature. Heavy injuries or damages will be the consequence. If it is necessary you have to
install a protective device.
5.4 Mounting / Disassembly
The mechanical mounting is identical in all variants. It differs only by the type of connection.
Observe the flow direction which is specified on the valve body.
Remove all transport safety devices (e.g. plugs or caps). Observe that there won`t be any parts of
the package or other pollution in the armature.
Before mounting the solenoid valve clean up the pipes. Pollution will reduce the safety and the
duration of life of the valve. If necessary mount a Y- strainer in front of the valve..
Avoid strains on the body by non align pipes.
5.4.1 Mounting of the valve with threaded connection
Before lay on sealing compounds, check the hardly screwing of the pipes into the valve body.
Lay on the correct sealing compounds on the pipes end. By using PTFE- ribbon or hemp sealings
observe the screw direction. Don`t use sealing compounds which are not prescribed for your
employment.
Screw the pipes into the connection ends of valve. Don´t use the handwheel as a lever.
tends for harden it.
sealing compound
harden!
o.k.
flow direction
Fig. 5.1 - Globe valve, Gate valve, Needle valve, mounting threaded connection ( Art. TC101025)
5.4.2 Mounting of the valve with welded connection
Before welding the valve between the pipes you have to disassemble the valve top first, to pre-
vent the damage of the sealings.
5.4.2.1 Disassembly of the valve`s top
Clamp the valve between a vice carefully. By using guard plates you can prevent the damage of
the ends of the valve body.
Loosen the valve top by using a fit spanner. Put the spanner onto the hexagon of the screw joint
and not onto the hexagon of the gland screw.
Screw the valve top out of the valve body and put it aside. Place a mark on the valve top and the
body that you will be able to join the correct parts by a subsequent mounting of the valve.
Fig. 5.2 - Globe valve, Gate valve, Needle valve, disassembly of the valve top
5.4.2.2 Welding the body between pipes
The safety demands be welding are depending on the place and the position of the point of weld.
Welding the parts in a serviceable device/machine/plant the potential of danger is as higher as
If appropriate inform the shift foreman / safety engineer or the works manager and the fire brigade
of your factory.
By welding observe your own national guide lines about safety and the prevention of accidents.
Globe valve, Gate valve, Needle valve
o.k.
flow direction
Fig. 5.3 - Globe valve, Gate valve, Needle valve, mounting with welded connection
5.4.2.3 Mounting of the valve top
Before mounting let the valve body cool down.
Screw the valve top into the body.
Check the correct position of the sealing at the screw joint and take care that there will be no
pollution on the sealing or on the seat.
Fasten the valve top with a fit spanner. Put the spanner onto the hexagon of the screw joint and not
on the hexagon or the gland screw.
cool down!
o.k.
Fig. 5.4 - Globe valve, Gate valve, Mounting of the valve top
5.4.3 Mounting of the valve with flanged connection
and the valve (welded flanges) and they are cooled down..
Push the valve between the flanges by using the appropriate sealings. This process must happen
easily to avoid the damage of the sealings.(Please refer to Fig. 5.5)
Align the borings of the flanges and put some fit screws through the holes.
Screw the fit nuts onto the screws and tighten them up crosswise.
Fasten all screws crosswise and check the function of the valve. Observe the maximum torque of
the screws.
o.k.
flow direction
Fig. 5.5 - Globe valve, Gate valve, mounting with flanged connections
5.5 Maintainance
Before you maintain or shut down the valves you have to read the
Safety advice
to this page.
In periodical turns the controlling of the function and the tightness should happen:
• Check the tightness of the gland packing

• resp. readjusting of the gland packing
If you determinate that there is a demage to the valve switch off the device/ machine/ plant!
However before doing this, it is essential to refer to the
Safety advice.
5.5.1 Gland
The sealing of valve takes place by a gland packing. For decreasing tightness the gland could be
readjust. By keeping the nominal pressure you have to tighten up the screw of the gland until the
tightness of the the gland will be restored.(Please refer to Fig. 5.6)
After the readjusting the handwheel of the valve must be able to move slightly.
tightness
o.k.
Fig. 5.6 - Globe valve, Gate valve, Needle valve; Readjusting of the gland
(2) as defined by Pressure-Equipment-Directive 97/23/EG
AA, AB, AC, AD, AG, AR, BE, BF, BG, BH, BK, CA, CB, CD, CK, CU, CV, CW, EA, EA, EB, EK, FG, IC, IG, IK,
IL, KA, KU, MA, MB, MD, MR, NG, PB, PD, RG, RK, RM, SD, SV, TA, TB, TC, TD, TE, TF, TH, TR, UV, VA, VC,
VD, VH, VK, VL, VM, VN, VO, VT, VU, WG, ZA, ZE, ZF, ZG, ZK, ZP, SONV, and all variants of these articles

Germany
(7) Notified body for conformity assessment PED an Quality-Management-System:
Bureau Veritas S.A.

Paris / Frankreich
Kennzeichen 0062

(9) On behalf Bad Oeynhausen, 25. Mai 2002


PRODUCTS
We are developing and producing sophisticated industrial fittings proving every day in the field.
This is supported by our fulfilling the requirements of Quality Standard DIN EN ISO 9001.
Satisfied partners and success are proving that the investment for qualitiy and protection of the
invironments is worthwhile.
END-ARMATUREN GMBH & CO. KG END-AUTOMATION GMBH & CO. KG

OBERBECKSENER STR.78 OBERBECKSENER STR.78
D-32547 BAD OEYNHAUSEN D-32547 BAD OEYNHAUSEN
POSTFACH (PLZ 32503) 100 341 POSTFACH (PLZ 32503) 100 342
TELEFON +49 (0) 5731 / 7900-0 TELEFON +49 (0) 5731 / 7901-0
TELEFAX +49 (0) 5731 / 7900-80 TELEFAX +49 (0) 5731 / 7901-98
INTERNET http://www.end.de INTERNET http://www.end.de
E-MAIL post@end.de E-MAIL post@end.de
Operation manual
BSPV0006EN
Pressure relief valve SPV / SPVF
BSPV0006EN_D0024980002_01
Englisch
2010-05-27
Table of Content
1 General points 4
1.1 About the documentation 4

1.2 Manufacturer´s address 4
1.3 Intended use 4
2 Safety 6
2.1 Safety instructions and symbols 6

2.2 Staff qualification and training 6
2.3 General safety instructions 6
2.4 Hazard statements 7
3 Device description 9

3.2 Flow direction 10
3.3 Basic construction 10
3.4 Dimensions 11
3.4.1 SPV 10 (EN-GJL-300) 11
3.4.2 SPV 10 (EN-GJS-400-15) 12
3.4.3 SPVF 20 - 80 13
3.4.4 SPVF 20 - 80 Table 14
3.4.5 SPVF 50 - 80 (EN-GJS-400-15) 15
3.4.6 SPVF 50 - 80 Table (EN-GJS-400-15) 16
3.5 Types of seals 16
3.6 Type key SPV / SPVF 10-80 17
4 Technical data 18
4.1 General characteristics 18

4.2 Hydraulic specifications 18
4.3 Overview materials 19
4.4 pE-Q characteristic curves (at 34 mm²/s) 20
5 Transport and storage 21
5.1 Transport damage 21

5.2 Transport 21
5.3 Corrosion protection 21
6 Installation 23

6.2 Connection 23
7 Operation start-up 25
7.1 Preparation 25
7.2 General points about operation start-up 25
7.3 Further operation start-up 26
8 Removal 27
8.1 Removal Valve 27

9 Maintenance 28

9.2 Unusual noises 29
9.3 Static seals 29
9.4 Screw joints 29
9.5 Surface temperature 30
10 Repairs 31

10.2 Troubleshooting 31
10.3 Elimination of damage 31
10.4 Return 31
10.5 Detecting and eliminating problems 32
1 General points
1.1 About the documentation
These operating instructions describe the installation, operation and mainte-

nance of the pressure relief valves, type SPV, also referred to below as the
device.
The device is manufactured in different versions. Information about the ver-
sion concerned in the individual case can be found on the device's type plate.
The structure of the type designation and a more detailed description of the
individual series and nominal sizes can be found in the chapter "Technical
data" and in the chapter "Device description".
If you have any questions about this operating manual, please contact the
manufacturer.
1.2 Manufacturer´s address
Kracht GmbH
Gewerbestraße 20
DE 58791 Werdohl
phone: +49 (0) 23 92 / 935-0
fax: +49 (0) 23 92 / 935-209
email: info@kracht.eu
web: www.kracht.eu
1.3 Intended use
The SPV/ SPVF pressure relief valve is a directly-controlled slide valve for
installation in pipelines and is used to secure low-pressure hydraulic circuits
up to pmax 20 bar - in exceptional cases, 30 bar. Each maximum permissible
setting pressure is predetermined by the pressure rating in the type key. The
various seal variants and materials enable the use of different media.
The device has been designed for operation with fluids. Dry operation is not
permitted. The medium must guarantee a minimum lubrication.
It must be guaranteed that the medium is compatible with the materials used
in the device (see chapter "Overview materials")
The maximum permissible operating data listed in the "Technical data" chap-
ter must always be observed.
4 2010-05-27 BSPV0006EN_D0024980002_01
Deviations from the above-mentioned data and operating conditions require

express approval by the manufacturer and/or are specified on the type plate.
Type plates or other references on the device must not be removed nor made
illegible or irrecognisable.
In cases of noncompliance, all warranty claims and manufacturer responsi-
bility shall be void.
BSPV0006EN_D0024980002_01 2010-05-27 5
2 Safety
2.1 Safety instructions and symbols
The safety notices in these operating instructions are marked with caution
symbols.
Non-compliance can lead to hazards for people and the device.
In addition, the safety instructions are marked with signal words. They have
the meanings as explained below:
Caution: Identification of a low risk hazard, which could lead to minor or
medium bodily injury if not avoided.
Warning: Identification of a potential medium risk hazard, which would lead
to death or severe bodily injury if not avoided.
Danger: Identification of an immediate hazard, which would result in death
or severe bodily injury if not avoided.
Notice: Flagging of notices to prevent property damage.
Flagging of special user tips and other especially useful or important infor-
mation.
2.2 Staff qualification and training
The staff designated to install, operate and maintenance the device must be
properly qualified. This can be through training or specific instruction. Staff
must be familiar with the contents of this operating manual.
2.3 General safety instructions
The operational safety of the device delivered is only guaranteed when it is

used for the intended purpose (see chapter "General points").
The limit values given must never be exceeded (see chapter "Technical
data").
National regulations concerning accident prevention and health and safety
at work must be observed, as well as internal regulations laid down by the
operator, even if these are not specifically mentioned in this manual.
The operator must ensure that this operating manual is accessible to the
staff responsible at all times.
6 2010-05-27 BSPV0006EN_D0024980002_01
2.4 Hazard statements
DANGER
Hazard caused by valve blockage
Do not alter the pressure setting higher than each permissible pressure
value. Improper adjustment can block the valve actuator, resulting in haz-
ardous pressure increases.
DANGER
may be used.
DANGER
DANGER
DANGER
Hazard caused by pressurised pipelines
The connection pipelines must be made pressure-less before any work is
done on the device and prior to removal.
CAUTION
above 60°C.
BSPV0006EN_D0024980002_01 2010-05-27 7
CAUTION
8 2010-05-27 BSPV0006EN_D0024980002_01
3 Device description
3.1 General points
The SPV/ SPVF Pressure Relief Valve is a directly-operated sliding piston

valve for installation in pipelines and is used to secure low-pressure hydraulic
circuits up to pmax 20 bar (30 bar). Pipe connection is to be effected either by
SAE flange (3000 psi) or Whitworth pipe thread (G).
Fig. 3.1:
The sliding piston 2 is pressed against the annulated area a by the compres-
sion spring 3, resulting in the pump connection P being separated from the
reservoir connection R by the diameter d. As soon as the operating pressure
p is achieved, adjusted by the set screw 4, the sliding piston 2 releases the
oil flow to the reservoir. The spring chamber b is pressure compensated by
the bore c. When the valve is put into operation, the spring chamber b must
be bled using the bleeding screw 5 (SW 4). The valve should preferably be
used in the vertical fitting position with the set screw facing downwards. In
this case, bleeding is not necessary.
BSPV0006EN_D0024980002_01 2010-05-27 9
3.2 Flow direction
The flow direction is marked with an arrow on the device housing. It is always
implemented from connection P to connection R.
3.3 Basic construction
Tab. 3.1: Basic construction SPV / SPVF
10. Housing 80. Set screw

20. Valve piston 90. Socket head cap screw
30. Cap screw 100. Round head grooved pin
40. Spring guide 110. O-Ring
50. Compression spring 120. Sealing ring
60. Type plate 130. Union nut
70. Threaded protective cap
10 2010-05-27 BSPV0006EN_D0024980002_01
3.4 Dimensions
3.4.1 SPV 10 (EN-GJL-300)
Tab. 3.2:
SPV 10 A1G 1 A .. SPV 10 B1G 1 A .. SPVM 10 A1G 1 A ..

SPV 10 C1G 1 A .. SPV 10 D1G 1 A .. SPVM 10 C1G 1 A ..
Tab. 3.3:
SPV 10 A1G 1 B .. SPVM 10 A1G 1 B .. SPV 10 A1G 1 A .. - ATEX

SPV 10 C1G 1 B .. SPVM 10 C1G 1 B .. SPV 10 A1G 1 A .. - ATEX
BSPV0006EN_D0024980002_01 2010-05-27 11
3.4.2 SPV 10 (EN-GJS-400-15)
Tab. 3.4:
SPV 10 E1G 1 A .. SPV 10 E1G 1 B ..

SPV 10 K1G 1 A .. SPV 10 K1G 1 B ..
Tab. 3.5:
SPV 10 E1G 1 A .. - ATEX

SPV 10 K1G 1 A .. - ATEX
12 2010-05-27 BSPV0006EN_D0024980002_01
3.4.3 SPVF 20 - 80
Tab. 3.6:
SPVF . A2F 1 A .. SPVF . A1G 1 A ..

SPVF . C2F 1 A .. SPVF . C1G 1 A ..
Tab. 3.7:
SPVF . B2F 1 A .. SPVF . B1G 1 A ..

SPVF . D2F 1 A .. SPVF . D1G 1 A ..
BSPV0006EN_D0024980002_01 2010-05-27 13
3.4.4 SPVF 20 - 80 Table
Tab. 3.8:
NW 20 25 32 40 50 80
SAE-Flange 3/4" 1" 1 1/4" 1 1/2" 2" 3"
Thread R G 3/4 G1 G 1 1/4 G 1 1/2 G2 G3
A 47,6 52,4 58,7 69,9 77,8 106,4
B 22,2 26,2 30,2 35,7 42,9 61,9
C M10 M10 M10 M12 M12 M16
D 59 59 72 83 97 131
E 70 70 79 94 102 135
F 24 24 32 38 50,5 79
G 20 20 20 20 20 25
H 50 50 65 65 75 110
K1 160 160 170 170 192 190
K2 167 167 172 172 209 207
L1 210 210 235 235 267 300
L2 217 217 237 237 284 317
M 50 55 65 65 75 110
Tab. 3.9:
Nominal size Weight

SW1 SW2 SW3 SW4 kg
20 17 5 46 17 3,0
25 17 5 46 17 3,5
32 17 5 46 17 5,5
40 17 5 46 17 6,0
50 19 6 46 19 8,2
80 19 6 - 19 18,5
14 2010-05-27 BSPV0006EN_D0024980002_01
3.4.5 SPVF 50 - 80 (EN-GJS-400-15)
Tab. 3.10:
SPVF . E2F 1 A .. SPVF . E1G 1 A ..

SPVF . K2F 1 A .. SPVF . K1G 1 A ..
Tab. 3.11:
SPVF . E2F 1 A .. - ATEX SPVF . E1G 1 A .. - ATEX

SPVF . K2F 1 A .. - ATEX SPVF . K1G 1 A .. - ATEX
BSPV0006EN_D0024980002_01 2010-05-27 15
3.4.6 SPVF 50 - 80 Table (EN-GJS-400-15)
Tab. 3.12:
NW SAE Flange Thread

R A B C D E F H K1 L1 L3 M
50 2" G2 77,8 42,9 M12 124 102 50,5 75 192 267 274 75
80 3" G3 106,4 61,9 M16 176 135 79 110 190 300 307 110
Tab. 3.13:
Nominal size Weight

SW1 SW2 SW3 SW4 kg
50 19 6 46 17 8,2
80 19 6 - 19 18,5
Production of the housing in version types "E" and "K" in the nominal sizes
20, 25, 32 and 40 has been changed from solid material to raw parts. The
cast contours correspond to the version made of EN-GJL-300 (for dimensions
see table on previous page)
3.5 Types of seals
There are 4 types of seal available:
Tab. 3.14:
Material
NBR Standard version up to 80 °C
FKM Version up to 150 °C
Copper High-temperature version up to 220 °C
Soft iron Maximum-temperature version up to 350 °C
16 2010-05-27 BSPV0006EN_D0024980002_01
3.6 Type key SPV / SPVF 10-80
Tab. 3.15: Ordering example SPV / SPVF 10-80
SPVF M 25 A 2F 1 A 12
1. 2. 3. 4. 5. 6. 7. 8.
Tab. 3.16: Explanation of type key SPV / SPVF 10-80
1. Product name
2. Installation (on request)
M Panel mounting (A and C possible)
3. Nominal size
10 20 25 32 40 50 80
Qmax= 40 Qmax= 90 Qmax= 90 Qmax= Qmax= 450 l/ Qmax= 550 l/ Qmax= 800 l/
l/min l/min l/min 450 l/min min min min
4. Version
A Standard version NBR up to 80 °C
B High-temperature version up to 220 °C
C FKM version up to 150 °C
D Soft iron seal up to 350 °C
E GJS-housing NBR
K GJS-housing with FKM seal
5. Pipe connection
2F SAE flange 3000 psi
1G Threaded connection
6. Construction code (specified internally)
7. Actuation type
A Set screw
B Knob (on request)
8. Pressure range (pressure levels)
02 05 07 12 20 25 30
0,5 ... 2.5 2 ... 5 bar 2 ... 7 bar 4 ... 12 10 ... 20 bar 19 ... 25 bar 10 ... 30 bar
bar (only NG bar (only NG 20 ... (only NG 10)
20 ... 40) 50)
BSPV0006EN_D0024980002_01 2010-05-27 17
4 Technical data
4.1 General characteristics
Tab. 4.1:
Construction Sliding piston valve - directly operated (seat on request)

Mounting in pipeline
Pipe connection SAE flange (3000 psi) / Whitworth thread G
Dimensions see chapter 3 "Dimensions"
Weight see chapter 3 "Dimensions"
Installation position Pressure set screw facing down
Housing material EN-GJL-300 ( EN-GJS-400-15)
Actuation type mechanical set screw/knob
Accessories Welding flange SAE (3000 psi)
∆p-Q-characteristics see chapter 4 "Characteristic curves"
Hydraulic oils Hydraulic oils according to DIN 51 524 / 25
(other media on request)
4.2 Hydraulic specifications
Tab. 4.2:
Nominal size 10 20/25 32/40 50 80

max. flow capacity l/min 40 90 450 550 800
Nominal pressure bar 30 25 25 25 20
Pressure setting range pv min bar 0,5 0,5 0,5 0,5 0,5
pv max bar 30 25 25 25 20
Fluid temperature range Tm min °C -20 -20 -20 -20 -20
Tm max °C 80 (220) 80 (220) 80 (220) 80 (220) (220)
Ambient temperature Tu min °C -20 -20 -20 -20 -20
Tu max °C 60 60 60 60 60
Viscosity min mm2/s 6
max mm2/s 600 (standard)
max mm2/s 1500 (possible) at Qmax= 50% QN and at pmax= 75% pN
18 2010-05-27 BSPV0006EN_D0024980002_01
4.3 Overview materials
Tab. 4.3: Materials SPV / SPVF
Housing see chapter 3.6 type key "Version"

Valve piston 16MnCrS5
Cap screw 9 SMnPb 28
Spring guide 15 S20K
Compression spring Spring steel C
Type plate Al 99.5
Threaded protective cap Polypropylene
Set screw Steel
Socket head cap screw Steel
Round head grooved pin Al 99.5
O-Ring see chapter 3.6 type key "Version"
Sealing ring Copper
Union nut Steel
BSPV0006EN_D0024980002_01 2010-05-27 19
4.4 pE-Q characteristic curves (at 34 mm²/s)
Tab. 4.4:
SPV 10
SPVF 20/25
SPVF 32/40
SPVF 50
SPVF 80
20 2010-05-27 BSPV0006EN_D0024980002_01
5 Transport and storage
5.1 Transport damage
Inspect the device for shipping damage as soon as the delivery has been
received.
If shipping damage is discovered, inform the shipping company.
If proper operation of the device is impaired by the damage, the device must
be replaced or repaired. In that case, contact the manufacturer.
5.2 Transport
DANGER
device.
5.3 Corrosion protection
The device's function is tested in the plant with mineral hydraulic oil. Then all
connections are closed. The remaining residual oil protects the interior parts
for about 6 months.
The device must not be exposed to the influence of the weather and major
fluctuations in temperature during transport and storage and must be stored
in a dry place.
If the device is stored over a longer period, it must be treated on the inside
and outside with a suitable corrosion protection oil. In addition, it must be
protected from humidity by a humidity-absorbing agent.
If high air humidity or aggressive atmosphere is to be expected during trans-
port, suitable corrosion prevention measures must be carried out.
BSPV0006EN_D0024980002_01 2010-05-27 21
NOTICE
Care must be taken that the preserving agent is compatible with the mate-
rials and elastomers used. In addition, compatibility with the media used
must be guaranteed.
22 2010-05-27 BSPV0006EN_D0024980002_01
6 Installation
6.1 General points
NOTICE
qualified staff.
clean.
6.2 Connection
The respective safety instructions must always be observed during all work
on the device.
● Before installation, the device must be checked for transport damage and
soiling.
● Any preserving agents must be removed before installation using ben-
zine or solvent.
NOTICE
The device should preferably be used in the vertical fitting position with the
set screw facing downwards.
Clean the pipework of dirt, scale, sand, swarf, etc. prior to installation. Wel-
ded pipes in particularly must be pickled or flushed. Cotton waste must not
be used for cleaning.
may be used.
During installation, make sure that no sealant gets into the pipeline. Sealing
agents such as hemp and putty are not permitted since they can lead to
soiling and thus to functional problems.
● Remove the protective plugs from the device connections.
BSPV0006EN_D0024980002_01 2010-05-27 23
DANGER
● Mount the pipelines at the device inlet and outlet.
DANGER
may be used.
NOTICE
the device.
CAUTION
above 60°C.
24 2010-05-27 BSPV0006EN_D0024980002_01
7 Operation start-up
7.1 Preparation
NOTICE
qualified staff.
clean.
● Check the permissible operating data against the operating states to be

expected.
7.2 General points about operation start-up
The pressure relief valves are set to the pressure specified by the customer.
The pressure setting may have to be corrected during operation start-up,
since different flow quantities, oil viscosities and pipeline lengths can cause
changes in the response value. In this case, a manometer must be installed
directly at the valve's pressure oil connection. Pressure is adjusted by re-
moving the protective cap pos. 50 and using an inbus key to loosen the
hexagon nut pos. 90 over the set screw pos. 80. Turning clockwise increases
pressure, turning anti-clockwise decreases pressure. After the required set
pressure has been reached, the hexagon nut pos. 90 must be tightened and
the protective cap pos. 50 replaced.
Pressure relief valves can only work perfectly when all the chambers in the
valve are filled with hydraulic fluid. If the valve is installed in an unfavourable
position, air can be collected in the chambers and lead to vibration noise. In
such cases, bleed the valve. To do this, loosen the bleeding screw pos. 100
by one revolution. Bleeding should be carried out at low pressure and is fin-
ished when the oil being released is without bubbles. Then tighten the
bleeding screw again.
DANGER
Hazard caused by setting the stud bolt
While doing so, screw in the stud bolt only until the maximum pressure of
each pressure rating has been reached.
BSPV0006EN_D0024980002_01 2010-05-27 25
7.3 Further operation start-up
Special conditions or restrictions are applicable for safe operation of the de-
vice. These have to be ensured by the customer or operator by means of
suitable technical and/or organisational measures.
● The medium must have a minimum lubricating ability.
● The ambient conditions specified in the operating manual must always
be complied with.
● The device may only be used at usual industrial atmosphere or sub-
mersed in the medium. Always consult the manufacturer if there are
aggressive substances in the air.
● The device has only been approved for operation with the substances
specified in the operating manual.
● Protect the device from impact effects.
● Any bleeding or draining screws must always be closed during proper
use.
● A filter must be installed if required to avoid faulty device function caused
by soiling or contaminants.
● Operation is not permitted outside the approved parameters.
● The installation, servicing and repair specifications contained in the op-
erating manual must always be complied with.
● The device may only be operated with a connected tank pipe that leads
into a tank or other suitable tank.
● The device must be fitted and monitored in line with the applicable tech-
nical regulations. During device set-up and operation, the requirements
of the respective guidelines, standards etc. must be complied with.
● The condition of the service fluid must be checked regularly within the
context of normal system servicing for soiling, decomposition, changes
in composition etc..
Further instructions and more detailed specifications about the individual
points can be found in the respective chapters of this operating manual.
26 2010-05-27 BSPV0006EN_D0024980002_01
8 Removal
8.1 Removal Valve
DANGER
DANGER
Hazard caused by pressurised pipelines
CAUTION
NOTICE
qualified staff.
clean.
the system.
● Remove the depressurised pipelines from the pump.

● Seal the device connections and pipelines to prevent dirt penetration.
BSPV0006EN_D0024980002_01 2010-05-27 27
9 Maintenance
9.1 General points
NOTICE
Regular maintenance is essential for safe operation. Scope and intervals
must be adapted to requirements. The first check-up must be carried out
directly after the device has been put into operation.
The length of maintenance intervals must be defined by the operator. Dur-
ing visual inspections, particular attention must be paid to possible damage.
In this case, the device may no longer be used.
Type and scope of maintenance as well as measured values should be
documented. This is the quickest way to determine changes in operating
data.
When designed to the conditions of use and fitted correctly, the devices are
able to be used for long and problem-free operation. They only require a little
maintenance. This is absolutely essential for problem-free operation, howev-
er. Experience shows that a high percentage of the problems and damage
that occur can be traced back to dirt and lack of maintenance.
The scope and time intervals for inspections and maintenance are generally
specified by the operator in a respective plan.
Regular checking of all operating data such as pressure, temperature, cur-

rent consumption, degree of filter soiling etc. contributes to early problem
detection.
NOTICE
clean. The surrounding external area must be cleaned before screw joints
are loosened.
It must also be guaranteed that no pressure can build up again during work
on the device.
Repair, servicing and installation work may only be carried out by trained
and professionally qualified staff.
When the device is disassembled, the components must always be pro-
tected from damage and soiling.
28 2010-05-27 BSPV0006EN_D0024980002_01
CAUTION
DANGER
DANGER
9.2 Unusual noises
Some damage is indicated by unusual noises. If there is a change in the de-

vice's operating noise, a thorough examination of the cause must always take
place.
9.3 Static seals
The static seals on the device's separation joints and the connection lines
must be periodically checked for leakproofness.
If there are any visible leaks, immediately stop plant operation.
If the leaks cannot be stopped by simply retightening the connection, replace
all affected seals.
9.4 Screw joints
All the screw joints must be checked at regular intervals to make sure they
are a tight fit. Loose screw joints must be tightened and, if necessary, secured
against loosening by e.g. Loctite (medium strength).
BSPV0006EN_D0024980002_01 2010-05-27 29
9.5 Surface temperature
The temperatures on the device's surface can be checked to prevent prema-

ture wear or detect device overload. This temperatures should never be much
higher than the media temperature at the device inlet. If the temperature on
the device's surface is much higher, this is an indication of a device malfunc-
tion. In this case the device must be replaced immediately.
30 2010-05-27 BSPV0006EN_D0024980002_01
10 Repairs
10.1 General points
The term repairs covers:

● Troubleshooting, in other words establishing damage, determining and
localising the reason for the damage.
● Elimination of the damage, in other words eliminating the primary cau-
ses and replacing or repairing faulty components.
10.2 Troubleshooting
Leaks are the most frequent problem. If these occur on the pipelines, they
can be eliminated by straightforward tightening of the screw joints.
If the device itself is leaking, the respective seals have to be replaced (see
spare parts list).
10.3 Elimination of damage
Repair damage onsite, predominantly by replacing the defective device. The

device itself is generally repaired by the manufacturer.
If corresponding expertise and sufficient equipment is available, the consum-
er or OEM can also make the repairs. For support, spare parts lists and
sectional drawings are available. They can be requested from the manu-
facturer.
NOTICE
Repair work may only be carried out by trained and professionally qualified
staff. Only original spare parts may be used.
10.4 Return
If the device has to be repaired or checked over on the manufacturer's prem-

ises, it must be packed suitably for transport. In addition, a safety data sheet
for the medium used must be enclosed with the device. In the case of well-
known mineral oils, at least the exact type description is required.
If hardening or agglutinative media are involved, the device must be cleaned
before it is returned.
Cleaning is also necessary if the device has been operated with hazardous
fluids.
BSPV0006EN_D0024980002_01 2010-05-27 31
10.5 Detecting and eliminating problems
The following table lists the possible causes of the most frequently occuring
malfunctions and notes on possible remedies.
If the problems cannot be identified, please request help from the manufac-
turer.
Tab. 10.1:
Fault Possible cause Remedy

Leak, O-ring(s) leaking Check seal compatibility, consult the manufactur-
media escaping er if necessary and fit new O-ring(s) (purchase
from the manufacturer)
Opening pressure Valve piston stiff Clean or replace the valve
too high
Operating pres- Set screw for pressure Compare the opening pressure with the permissi-
sure too high setting screwed in too ble opening pressure of the respective pressure
deep level
Noise Air inside the valve Bleed the valve and/or system
32 2010-05-27 BSPV0006EN_D0024980002_01
1440013 /11 IM-S02-13
ST Issue 11
FT14
Ball Float Steam Trap ½" (DN15) to 1" (DN25)
Installation and Maintenance Instructions
1. General
safety information
2. General
product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
Printed in the
IM-S02-13 STUK
Issue 11 © Copyright 2005
1
1. General safety information
Safe operation of the unit can only be guaranteed if it is properly installed, commissioned
and maintained by a qualified person (see Section 11 of the attached Supplementary
Safety Information) in compliance with the operating instructions. General installation
and safety instructions for pipeline and plant construction, as well as the proper use of
tools and safety equipment must also be complied with.
Warning
The cover gasket contains a thin stainless steel support ring which may cause physical
injury if not handled and disposed of carefully.
Isolation
Consider whether closing isolating valves will put any other part of the system or
personnel at risk. Dangers might include; isolation of vents and protective devices or
alarms. Ensure isolation valves are turned off in a gradual way to avoid system shocks.
Pressure
Before attempting any maintenance consider what is or may have been in the pipeline.
Ensure that any pressure is isolated and safely vented to atmospheric pressure before
attempting to maintain the product, this is easily achieved by fitting Spirax Sarco
depressurisation valves type DV (see separate literature for details). Do not assume
that the system is depressurised even when a pressure gauge indicates zero.
Temperature
Allow time for temperature to normalise after isolation to avoid the danger of burns and
consider whether protective clothing (including safety glasses) is required.
Disposal
This product is recyclable. No ecological hazard is anticipated with the disposal of this
product providing due care is taken.
2 IM-S02-13 ST Issue 11
2. General product information
2.1 General description
The FT14 is an SG iron ball float steam trap with integral automatic air venting facility.
It is available with screwed or flanged horizontal connections with flow from right to left (R-L)
or left to right (L-R). The screwed version is also available with vertical connections (FT14V)
with flow downwards.
If required the flanged version can be modified on site to the vertical orientation.
2.2 Optional extras

An optional steam lock release (SLR) valve (designated 'C' on the nomenclature)
FT14C can be fitted to the trap to prevent steam locking of the system, this feature is
available in addition to the air vent.
FT14X Optional integral strainer screen.
Standards
The product fully complies with the requirements of the European Pressure Equipment
Directive 97 /23 /EC.
Certification
This product is available with material certification to EN 10204 2.2.
Note: All certification /inspection requirements must be stated at the time of order placement.
Fig. 1 Fig. 2
FT14 (R-L) screwed FT14C (R-L) screwed
Main valve assembly size 1"
Fig. 3 Fig. 4
FT14 (R-L) flanged FT14C (R-L) flanged
IM-S02-13 ST Issue 11 3
2.3 Sizes and pipe connections
½", ¾" and 1" screwed BSP or NPT.
DN15, DN20 and DN25 standard flange PN16, ANSI 150, JIS 10 and KS 10.
2.4 Pressure /temperature limits (ISO 6552)

Pressure psi g
0 20 40 60 80 100 120 140 160 180 200 220
250 482
Temperature °C
Temperature °F
200 400
150 300
100 Steam
200
saturation
50 curve 100
0
0 2 4 6 8 10 12 14 16
Pressure bar g
The product must not be used in this region.
Body design conditions PN16

PMA Maximum allowable pressure @ 120°C (248°F) 16 bar g (232 psi g)
TMA Maximum allowable temperature 250°C (482°F)
Minimum allowable temperature 0°C (32°F)
Maximum operating pressure
PMO 14 bar g (203 psi g)
for saturated steam service
TMO Maximum operating temperature @ 12 bar g (174 psi g) 250°C (482°F)
Minimum operating temperature 0°C (32°F)
Maximum FT14-4.5 4.5 bar (65.25 psi g)
DPMX differential FT14-10 10 bar (145 psi g)
pressure FT14-14 14 bar (203 psi g)
Designed for a maximum cold hydraulic test pressure of: 24 bar g (348 psi g)
3. Installation
Note: Before actioning any installation observe the 'Safety information' in Section 1.
Refering to the Installation and Maintenance Instructions, name-plate and Technical Information
Sheet, check that the product is suitable for the intended installation.
3.1 Check materials, pressure and temperature and their maximum values. If the maximum
operating limit of the product is lower than that of the system in which it is being fitted,
ensure that a safety device is included in the system to prevent overpressurisation.
3.2 Determine the correct installation situation and the direction of fluid flow.
3.3 Remove protective covers from all connections and the protective film from all name-plates
before installation on steam or other high temperature applications.
Installation note:
- If the trap is to discharge to atmosphere ensure it is to a safe place, the discharging fluid
may be at a temperature of 100°C (212°F).
- The trap must be fitted with the float arm in a horizontal plane so that it rises and falls
vertically, therefore the arrow on the name-plate must point downwards.
- Unless specified, traps will be supplied with horizontal connections and with
right to left flow (R-L). Traps can be supplied with vertical connections with flow
from top to bottom or horizontal connections with flow from right to left (R-L) or left to
right (L-R).
- The connection orientation can be changed on site by undoing the four cover bolts
and moving the cover to the preferred orientation. A new gasket must always be fitted.
- Minimum withdrawal distance to remove cover is 105 mm (4.13").
Installation of the Steam Lock Release Unit (SLR)

3.4 The SLR valve is fitted to all float traps where a suffix 'C' is hard stamped on the nameplate
e.g. FT14-10C. 'C' = Combined steam lock release and thermostatic air vent (TV).
3.5 Check if the application requires the SLR valve for correct operation. The SLR should
only be used to prevent 'steam locking' and therefore is designed to pass only a
small amount of steam.
3.6 The SLR unit will be dispatched, pre-set to a partial bleed condition. The unit should
be screwed clockwise to close and anticlockwise to open. When required the
SLR should be used as a controlled continuous bleed, it is not recommended that
the SLR be left in the fully open condition as this may lead to premature trap failure and
more frequent maintenance schedules.
Warning
The cover gasket contains a thin stainless steel support ring which may cause physical injury
if not handled and disposed of carefully.
Please consult Spirax Sarco should further information be required.
4. Commissioning
After installation or maintenance ensure that the system is fully functioning. Carry out tests on
any alarms or protective devices.
5. Operation
The float trap is a continuous discharge trap, removing condensate the instant it forms. On
start-up, the thermostatic air vent allows air to bypass the main valve preventing the system air
binding. Hot condensate will close the air vent tightly, but as soon as it enters the main chamber
of the trap, the float rises and the lever mechanism attached to it opens the main valve - keeping
the system drained of condensate at all times. When steam arrives, the float drops and closes
the main valve. Float traps are renown for their high start-up load handling capability, clean
tight shut-off and resistance to waterhammer and vibration.
6. Maintenance
Note: Before actioning any maintenance program observe
the 'Safety information' in Section 1.
Warning
The cover gasket contains a thin stainless steel support ring which may
cause physical injury if not handled and disposed of carefully.
6.1 General information:

Before undertaking any maintenance on the trap it must be isolated from both the supply line and
return line and any pressure allowed to safely normalise to atmosphere. The trap should then be
allowed to cool. When reassembling, ensure that all joint faces are clean.
6.2 How to fit the main valve assembly:

- Undo the cover bolts (2) and lift off the body (1).
- Remove the complete float assembly by undoing the two screws (7).
- Remove the main valve seat (5) and replace with a new one supplied with new gasket.
Note: A valve spring (item 16) is fitted to the 1" traps only.
- Fit a complete new float assembly by tightening the assembly set screws (7) to the
recommended torque (see Table 1).
- Refit the body (1) using a new gasket (3).
6.3 How to fit the air vent assembly:

- Remove the spring clip, element and spacer plate (9).
- Unscrew the seat.
- Fit a new gasket, seat and frame.
- Assemble the spacer plate, fit element and clips.
- Align the complete air vent horizontally so that the frame clears the cover.
6.4 How to fit the Steam Lock Release (SLR) assembly:
- Unscrew the complete SLR assembly (12) and (14).
- Remove the SLR gasket (13).
- Replace the SLR assembly and washer with new ones.
- Reset the SLR to the desired bleed rate.
Table 1 Recommended tightening torques
or
Item Nm (lbf ft)
mm
2 17 A /F M10 x 30 47 - 50 (35 - 37)

5 17 A /F 50 - 55 (37 - 40)
7 Pozidrive M4 x 6 2.5 - 3.0 (1.8 - 2.2)
9 17 A /F 50 - 55 (37 - 40)
12 + 14 19 A /F 50 - 55 (37 - 40)
Steam lock release Air vent

assembly assembly
12 + 14 13 1 6 9 3
Frame
Seat
16
2 6 5 11 10 7 1" only 8 3
Main valve
assembly
Fig. 6
7. Spare parts
The spare parts available are shown in solid outline. Parts drawn in broken line are not
supplied as spares.
Available spares
Main valve assembly with float 3, 5, 6, 7 (2 off), 8, 10, 11, 16 (1" only)
Air vent assembly 3, 6, 9
Steam lock release unit and air vent assembly (FT14C only) 3, 6, 9, 12 + 14, 13
Cover gasket (packet of 3) 3
Maintenance kit 3, 5, 6, 7, 8, 9, 10, 11, 16 (1" only)
How to order spares

Always order spares by using the description given in the column headed 'Available spares'
and state the size and type of trap.
Example: 1 - Air vent assembly for a Spirax Sarco DN20 FT14-10 (R - L) ball float steam trap.
Steam lock release Air vent

assembly assembly
12 + 14 13 6 9 3
16
6 5 11 10 7 1" only 8 3
Main valve assembly
Fig. 7
D Einbau- und Bedienungsanleitung
GB Fitting and operating instructions 17-4-1
F Instructions pour le montage et l’entretien
Wartungseinheiten
Filterregler - Nebelöler
Service units
filter regulator – oil-mist lubricator
les groupes de surveillance

détendeur à filtre- lubrificateur
Wartungseinheiten, aus Filter- Air treatment units normally consisting Les groupes de surveillance, composés
regler und Öler bestehend, haben die of filter regulator, and fog lubricator are normalement d'un détendeur à filtre, et
Aufgabe, Druckluft als Betriebsmittel intended for cleaning compressed air for d'un lubrificateur à brouillard d'huile, ont
von flüssigen und festen Bestandteilen workshop purposes from liquid and solid pour fonction d'épurer l'air comprimé
zu reinigen, den Luftdruck zu regeln und contamination, for pressure regulation and servant d'agent moteur en le
die Luft mit feinst vernebeltem Öl zur for providing a fine oil spray for the débarrassant des particules liquideset
Schmierung von Zylindern, Ventilen, lubrication of cylinders, valves, compressed solides, de réguler la pression d'air et
druckluftgesteuerten Werkzeugen und air controlled tools ect. d'imprégner l'air avec un brouillard d'huile
dergleichen zu durchsetzen. In richtiger, When used correctly and in accordance extrêmement fin pour le graissage des
den jeweiligen Betriebsverhältnissen with the respective operating conditions, cylindres, soupapes, outils pneu-
entsprechender Anwendung erhalten they maintain the performance level of matiques, etc.
sie den Leistungsgrad pneumatischer pneumatic plant and increase its service Utilisés de façon adéquate, en fonction
Anlagen und erhöhen deren life. Our special brochures covering air des conditions de service correspon-
Lebensdauer. Eine übersichtliche Dar- treatment units contain the sizes and types dantes, ils contribuent à conserver aux
stellung der einzelnen Typen und with all details in a clearly arranged table installations pneumatiques leur puissance
Größen in unserem Hauptkatalog und thus facilitating selection according to the et à prolonger leur durée de vie. La
die technischen Details in unseren operating requirements. description très claire et les détails
Datenblättern erleichtert die richtige techniques donnés par nos dépliants
Auswahl nach Maßgabe der Betriebs- spéciaux sur les différents types et
ansprüche. dimensions de groupes de surveillance
facilitent un choix adéquat en fonction des
© Riegler 17-4-1
exigences d'exploitation.
Einbau Fitting Montage
In Pfeilrichtung, so nah wie möglich an Sequence (in direction of arrow) in normal Le montage s'effectue normalement
den Verbraucher (max. 10m vor dem cases: filter regulator - fog lubricator; the (dans le sens de la flèche) dans l'ordre
Verbraucher). distance between the air treatment unit and suivant: détendeur à filtre - Lubrifica-
Einbaulage vertikal, bezogen auf die the consumerpoint should be as short as teur à brouillard d'huile, et ce à la plus
Behälter. possible. The units must be mounted faible distance possible du point de
vertically. prélèvement.
04/05 techn.Änderungen vorbehalten 1.1

17-4-1 Druckluftaufbereitung
Filterregler Filter regulator Dètendeur à filtre
Filter Filter Filtre
Druckluft enthält Kondenswasser, Rohr- Compressed air contains water condensate L'air comprimé contient de l'eau de con-
zunder, Rostteilchen, u.ä., die pneu- scale, rust particles etc. which attack densation, des oxydes de tuyauterie, des
matisch gesteuerte und betriebene pneumatically controlled and actuated tools particules de rouille etc. qui attaquent les
Werkzeuge, Druckzylinder, Ventile usw. such as compressed air cylinders, valves outils à commande ou entraînement
angreifen und auf deren Funktion störend etc. and which thus have a disturbing effect pneumatique, vérins, soupapes, etc., et
einwirken. Die Reinigung der Druckluft ist on their function. For this reason the perturbent leur bon fonctionnement. C'est
deshalb eine unerläßliche Notwendigkeit purification of compressed air is an pourquoi l'épuration de l'air comprimé est
und wird durch den Filter bewirkt. Der indispensable necessity and is undertaken une nécessité absolue, et elle est assurée
Reinigungsgrad ist von der Porenweite with the aid of filters. The filtering effect is par le filtre. Le degré d'épuration
(normal 40µ) des Sinterfilters abhängig. dependent on the pore diameter (normally (élimination des éléments solides et
Auf Wunsch können Sinterfilter mit 40µ) of the sintered filter. If required, liquides) dépend du diamètre des pores
geringerer Porenweite eingebaut werden. sintered filters with smaller pore diameter (normalement 40 microns) du filtre fritté.
can be fitted. Sur demande, nous pouvons monter des
filtres à pores de moindre diamètre.
Wartung: Kondenswasser regelmäßig ab- Servicing: Drain off the water condensate Entretien: Purger régulièrement l'eau de
lassen und Sinterfilter, wenn verschmutzt, at regular intervals and clean the sintered condensation et nettoyer le filtre fritté dès
reinigen. filter if it is dirty. qu'il est encrassé.
Ausbau: Behälter abschrauben, Removal: Unscrew the bowl. Dépose: Retirer la cuve,
Prallscheibe vom Sinterfilter lösen, Undo the twist plate from the sintered filter; dévisser l’écrou de fixation du filtre en
Sinterfilter herausnehmen. Sinterfilter in take out the sintered filter. Place the métal fritté et sortir ce dernier, le
Lösungsmittel legen (z.B. Benzin Tri usw.) sintered filter in a solvent (e.G. petrol, tricho remplacer par un filtre neuf. Replacer la
gut durchschwenken und trocknen, dann etc.), agitate well and dry. Replace the filter. cuve. Veiller à ce que le joint O-Ring soit
wieder einbauen. Auf einwandfreie Ensure that the seal is perfectly seated. For en parfait état.
Dichtung achten. cleaning of the plastic bowl, see the next
page.
Druckregler Pressure regulator Manodétendeur
Der Leitungsdruck einer Druckluftanlage The system pressure in a compressed air La pression existant dans la tuyauterie
schwankt entsprechend der Kompres- installation fluxuates according to the size d'une installation à air comprimé varie en
sorgröße (z.B. 6-10 oder 10-16 bar usw.). of the compressor (e.g. 6-10 or 10-16 bar fonction des dimensions compresseur (par
Druckregler reduzieren diesen etc.). Pressure regulators reduce this ex. 6 à 10 ou 10 à 16 bar). Les
schwankenden Leitungsdruck (Vordruck) fluxuating system pressure (upstream pres- manodétendeurs réduisent et stabilisent
auf den gewünschten Arbeitsdruck (Hinter- sure) to the desired working pressure cette pression variable (pression primaire)
© Riegler 17-4-1
druck) und halten diesen konstant. (downstream pressure) and maintain it à la pression de service désirée.
constant.
Für Wartungseinheiten werden Pressure regulators with reverse control are Pour les groupes de surveillance on utilise
Druckregler mit Rücksteuerung ver- used for air treatment units. Pressure normalement des manodétendeurs à
wendet. Druckregler mit Rücksteuerung regulators with reverse control offer the commande en retour, L'avantage de ces
haben den Vorteil, daß der Hinterdruck advantage that the downstream pressure appareils est qu'ils premettent de diminuer
ohne Luftentnahme durch Zurückdrehen can be reduced, without bleeding off air, by la pression sans prélèvement d'air, en
der Regulierschraube vermindert werden turning back the regulating screw. In dévissant la broche de réglage. Les
kann. Ferner werden die Rückstöße, addition, the blow-backs which occure in réactions qui se produisent avec les
welche bei pneumatischen Steuerungen pneumatic controls are vented to commandes pneumatiques, sont
auftreten, durch die Rücksteuerung, atmosphere by the reverse control (which at évacuées en outre dans l'atmosphère par
welche zugleich als Sicherheitsventil be- the same time can also be regarded as a la commande en retour gui fait en même
trachtet werden kann, in die Atmosphäre safety valve) thus protecting the pressure temps fonction de soupape de sûreté, ce
geleitet, wodurch das Manometer ge- gauge. qui a pour effet de protéger le manomètre.
schützt wird.
1.2 techn. Änderungen vorbehalten 04/05

Druckluftaufbereitung 17-4-1
Druckeinstellung: Handrad ziehen (Regler Pressure setting: Pull the adjusting knob, Réglage de la pression: Tourner
entriegelt), Druckregler durch drehen des or release the lock nut (Regulator ensuite le volant dans le sens des
Handrades auf den gewünschten Druck unlocked) then by tuning the knob adjust aiguilles d’une montre jusqu’à ce que
einstellen, Handrad drücken (Regler the pressure regulator to the desired le manomètre du détendeur indique la
verriegelt). pressure, finally press the adjusting knob, pression de service désirée. Bloquer
or set the lock nut (Regulator locked) down ensuite le volant à l’aide du bouton d’
to fix the unit set at the desired pressure. arrét.
Nebelöler Fog lubricator Lubrificateurs
Die Druckluft wird durch den Nebelöler mit The compressed air is enriched with a fine Grâce au lubrificateur, l'air comprimé
feinem Ölnebel angereichert und bewirkt in oil mist by the fog lubricator so that in this est enrichi d'un fin brouillard d'huile
diesem Zustand eine laufende und zuver- state it thus effects continuous and reliable et, dans cet état, assure un graissage
lässige Schmierung pneumatisch ge- lubrication of the pneumatically controlled constant et sûr des outils, vérins,
steuerter Druckluftwerkzeuge, Zylinder, compressed air tools, cylinders, valves etc. soupapes, etc. à commande
Ventile usw. pneumatique.
Bitte beachten: Mindestbetriebsdruck Please note: Minimum operating pressure Très important: La pression de ser-
0,5 bar. is 0,5 bar. vice minimale est de 0,5 bar.
Dosierung: Die Ölmenge (Tropfen pro Dosage: Set the amount of oil (drops per Dosage: Pendant la marche, régler le
Minute) während des Betriebes an der minute) on the dosaging screw as required débit d'huile (gouttes par minute)
Dosierschraube nach Bedarf einstellen. during operation. The number of drops can suivant besoin à l'aide de la vis de
Tropfenzahl im Schauglas ersichtlich. be seen in the sight-glass. dosage. Le nombre de gouttes peut
être contrôlé à travers le regard
transparent
Öleinfüllung: Einfüllschraube entfernen, Oil filling: Remove the oil filler screw. Remplissage d'huile: Dévisser le
Behälter bis zu Einfüllmarke (ca. 2/3) füllen. Fill the bowl to the upper mark (approx. 2/3 bouchon de remplissage, remplir le
Einfüllschraube gut schließen. Ölnach- full). Firmly replace the filler screw. It is réservoir jusqu'au repère (env. 2/3).
füllung während des Betriebes möglich, possible to replenish the oil during Bien revisser ensuite le bouchon de
die Luftzufuhr braucht nicht abgestellt operation; the air supply need not be shut remplissage. Le remplissage d'huile
werden. off. peut être effectué pendant la marche;
© Riegler 17-4-1
il n'est pas nécessaire de fermer

l'admission d'air.
Ölsorte: HL 25 nach DIN 51524-ISO VG Oil types: 22 - 46 cSt at 40°C. In special Sorte d'huile 22-46 cSt E 40°C .
32. In besonders gelagerten Fällen wende cases refer to the technical lubrication Dans les cas exceptionnels,
man sich an die schmiertechnischen service of the oil companys whose s'adresser aux services techniques de
Dienste der Ölgesellschaften, deren engineers are always available to give free graissage des sociétés pétrolières;
Ingenieure jederzeit unverbindlich und advice on all lubrication problems without leurs ingénieurs sont en tout temps à
kostenlos zur Beratung aller schmier- obligation. votre disposition pour vous conseiller
technischen Fragen zur Verfügung stehen. gratuitement et sans engagement sur
toutes les questions techniques
relatives au graissage.
04/05 techn. Änderungen vorbehalten 1.3

Tropfaufsätze: Für besondere Dome assembly: For special appli-

Fälle sind Tropfaufsätze aus Metall cations you need a dome assembly made
lieferbar. of metal.
Max. Betriebsdruck und Betriebs- Maximum operating pressures and Pression de service et température de
temperatur für Filter-Druckregler-und operating temperatures for pressure re- fonctionnement maxi.pour filtres et
Nebelöler: gulators and fog lubricators: lubrificateurs à brouillard d'huile:
max. Betriebsdruck bar max. operating pressure bar Pression de service maxi. bar
Kunststoffbehälter ohne Plastic bowl, with or without Cuve en matière plastique avec
oder mit Schutzkorb 16 protective cage 16 ou sans grillage de protection 16
Metallmantel 25 Metal casing 25 Cuve métallique 25
_______________________________ ________________________________ ________________________________
Betriebstemperatur °C Operating temperature C° Température de service C°

Kunststoffbehälter 0 bis + 50 Plastic bowl 0 to + 50 Cuve en matière plastique 0 à + 50
Metallmantel 0 bis + 60 Metal casing 0 to + 60 Cuve métallique 0 à + 60
Kunststoffbehälter dürfen nur mit Plastic bowls may only be cleaned Cuves en matière plastique
Wasser, Petroleum oder Waschbenzin using water, petroleum or spirit. Please «Makrolon»:
gereinigt werden. note: Petrol supplied for use in internal Les cuves en matière plastique doivent
Bitte beachten: Tankstellenbenzin ist combustion engines is not cleaning spirit. être nettoyées exclusivement avec de
kein Waschbenzin. l'eau, de l'essence rectifiée ou du
pétrole.
Benzin, Benzol, Aceton, trihaltige Benzine, benzole, acetone, cleaning Ne jemais utiliser de benzène, de
einigungsmittel oder ähnliches darf fluids containing tricho, or similar are l'essence normale ou super, de
keinesfalls zum Reinigen der Behälter under no cirumstances permitted for use l'acétone, de solvants contenant du
verwendet werden. Das Öl welches as cleaning agents for the bowl. The filling trichloréthylène ou d'autres produits
eingefüllt wird, darf mit keinen Flüssig- oil may not be thinned or blended with any analogues.
keiten, welche Weichmacher enthalten, fluid that contains emollients such as
z.B. Alkohol, Glysantin usw. verdünnt alcohol, "Glysantin" (antifreeze) etc.
bzw. vermengt werden.
Für Schäden, die durch Nichtbeachtung No responsibility can be accepted for Il ne faut jemais verser dans les cuves
dieser Vorschrift entstehen, kann keine damage which may result from non- ob- en Makrolon des liquides contenant des
© Riegler 17-4-1
Haftung übernommen werden. servance of these instructions. plastifiants tels que de l'alcool, du
glysantin etc.
Riegler & Co. KG, Schützenstr. 27 - 72574 Bad Urach Telefon (07125) 9497-0 Fax (07125) 949797

10 Measurement
Messtechnik
Important!
Wichtig!
10.1 Pressure Measurement
Druck-Messtechnik
Pressure Gauge
Druckmessgerät
Type 213.40
Pressure Transmitter
Drucktransmitter
10.2 Level Switch
Füllstandgrenzschalter
Type Liquitec
10.3 Water detector
Wasserdetektor
Type SK1-HT125

For further measuring instruments, please refer
to the instruction manual of the separator!
Weitere Messinstrumente finden Sie

gegebenenfalls in der Betriebsanleitung des
Separators!

1. Safety instructions nut is recommended to simplify correct orienta-
Operating tion of the gauge. When a blow-out device is
Instructions The user must ensure that the fitted to a pressure gauge it shall be resistant to
Pressure Gauges
! appropriate pressure gauge with
regard to scale range and performance
and the appropriate wetted material
blocking by debris and dirt.
With safety pattern gauges (see dial symbol k )
you need to pay attention to the fact that the
(corrosion) for the specific measuring free space behind the blow-out back will be at
conditions of the respective application is selec- least 15 mm.
ted. In order to guarantee the accuracy and
Examples: long-term stability specified, the corresponding 2.1 Requirements for the installation point
load limits are to be observed. Specifications:
If the measuring point is not adequately stable a
see data sheet under www.wika.de
measuring instrument support such as a bracket
Only qualified persons authorised by the plant or flange should be used for fastening (and
manager are permitted to install, maintain and possibly via a flexible capillary line). If the
Model 732.14,
service the pressure gauges. pressure gauge is exposed to vibration or
Overpressure safety pulsating pressure or both, then a liquid filled
Dangerous pressure media such as Oxygen,
up to 400 bar pressure gauge may provide considerably better
Acetylene, flammable gases or liquids, toxic
Model 432.36, performance and readability. Instruments should
gases or liquids as well as for refrigeration
Overpressure safety be protected against coarse dirt and wide
plants or compressors requires attention above
up to 400 bar fluctuations in ambient temperature. EN 837-2
the standard regulations. Here the specific
"Selection and installation recommendations for
Model 213.40 safety codes or regulations must be considered.
pressure gauges" should be complied with.
After an external fire pressure media can leak
out particularly at soft solder joints. All gauges 3. Admissible ambient and working
have to be checked and, if necessary, replaced temperatures
before recommissioning the plant. When installing the pressure gauge it has to be
Serious injuries and/or damage can occur ensured that, taking the influence of convection
should the appropriate regulations not be and heat radiation into consideration, no upper
observed. or lower deviation from the permissible ambient
Notes according to and medium temperatures can occur. The
Pressure Equipment Directive 97/23/EC influence of temperature on the class accuracy
2. Mechanical connection
T The pressure gauges are "pressure accessories" is to be observed.
According to the general technical regulations
in accordance with article 1, paragraph 2.1.4 for pressure gauges, respectively (i.e. EN 837-2). 4. Storage
T The volume of the pressure bearing housings of When screw-fitting the gauges the force The pressure gauge should remain in its original
WIKA pressure gauges is < 0.1 L required for this must not be applied through the packing until installation. The gauge should be
case or terminal box but just through the
T The pressure gauges carry the CE marking for protected from external damage during storage.
spanner flats (with suitable tool) provided for this Storage temperature: -40 °C ... +70 °C.
fluid group 1G in accordance with annex 2,
purpose. Pressure gauges removed from service should
table 1 when their permissible working pressure
exceeds 200 bar be protected from dust and humidity.
Pressure gauges that do not carry the CE marking Installation with
are manufactured in accordance with article 3, open-ended spanner 5. Maintenance and servicing / Repairs
paragraph 3 "sound engineering practice". The instruments require no maintenance or ser-
vicing. Tests should be carried out on a regular
Applied standard Correct sealing of pressure gauge connections
basis to guarantee the measuring accuracy of
with parallel thread ? shall be means of a
EN 837-1 Bourdon tube pressure gauges, Dimensions, the pressure gauge. The tests or recalibrations
suitable sealing ring, sealing washer or WIKA
metrology, requirements and testing have to be carried out by qualified persons with
EN 837-2 Selection and installation recommen- profile seals. The sealing of tapered threads (e.g.
the appropriate equipment.
dations for pressure gauges NPT threads) is made by providing the thread
EN 837-3 Diaphragm and capsule pressure gauges, @‚ with additional sealing material like, for
Remainder of the pressure medium
Dimensions, metrology, requirements and example, PTFE tape (EN 837-2).
testing
contained in the pressure element
may be hazardous or toxic. This
WIKA Alexander Wiegand GmbH & Co. KG Wrench surface Sealing of ! should be considered when handling
2408976 09/2006
Alexander-Wiegand-Straße 30 and storing the removed pressure

the thread @
63911 Klingenberg • Germany Sealing area ? gauge.
Phone (+49) 93 72/132-0
Fax (+49) 93 72/132-406 The torque depends on the seal used. With
E-Mail info@wika.de standard G-type pipe thread, gauge connection
www.wika.de by means of a union nut or a LH-RH adjusting Technical alteration rights reserved.
Betriebsanleitung 8251/53/55/57
Mode d'emploi Pressure Transmitter
Instructions NAT/NAH/NAE/NSL
Elektrischer Anschluss / Raccordement électrique / Electrical connection

Schutzart/Protection1) IP651) IP671)
Ausführung Industrial Standard M12x1

Exécution (DIN43650 C193)
4–pol. 5–pol.
Execution
01 32 35
Standard with accessory 95 with accessory 96
Ausgangssignal
Signal de sortie
Output
2 1 - - 4
1 3 - - 1
4 - - 5
825X.XX.XXXX.XX.19
1 1 1 1 2
2 2 3 4 4
3 3 4 3 3
4 2 2 5
825X.XX.XXXX.XX.14/16/17/23
1)
nur mit vorschriftsmässig montierter Kabeldose gültig
valable seulement avec fiche femelle montée selon instructions
provided with female connector is mounted according to instructions
Output Load resistance ISUPPLY USUPPLY

4 ... 20 mA (USupply-9V)/20mA 24(9 ... 32) VDC 825X.XX.XXXX.XX.19...
0 ... 5 VDC ≥2.0 kΩ ≤10 mA 24(9 ... 32) VDC 825X.XX.XXXX.XX.14...
1... 6 VDC ≥2.0 kΩ ≤10 mA 24(9 ... 32) VDC 825X.XX.XXXX.XX.16...
0... 10 VDC ≥5.0 kΩ ≤10 mA 24(15...32) VDC 825X.XX.XXXX.XX.17...
0.5... 4.5 VDC ≥2.0 kΩ ≤10 mA 5(4.5...5.5) VDC ratiometrisch/ ratiométrique/ ratiometric 825X.XX.XXXX.XX.23...
Einschaltverzögerung / Retard à l'enclenchement / Switch-on delay

1s
Anziehdrehmoment Druckanschluss / Couple de serrage raccord de pression / Torque moment pressure connection
max. 25Nm
Betriebstemperatur / Température de service / Operating temperature
NAT: -25°C...+85°C / NAH, NAE, NSL: -40°C...+125°C
Lagertemperatur / Température de stockage / Storage temperature
–25°C ... +85°C
Medientemperatur / Température de fluide / Media temperature
NAT: -25°C...+125°C / NAH, NAE, NSL: -40°C...+125°C

Betriebsdruck / Pression de fonctionnement / Operating pressure Achtung / Attention / Attention
Bereich 0 ... 0.2 Überdruck max. 0.5 Steckerausführung 01/34: Nur original Schraube verwenden!
Plage 0 ... 0.4 Surpression 1 Exécution fiche 01/34: Utilise seulement la vis originale!
Range 0 ... 0.6 Over pressure 1.5
Plug execution 01/34: Use only original screw!
(bar) 0 ... 1.0 (bar) 2
0 ... 1.6 3.5
0 ... 2.5 5
0 ... 4.0 12 Nicht an Kabeldose drehen.
0 ... 6.0 12 Ne pas tourne la fiche femelle
0 ... 10.0 20 Don't turn the female connector
0 ... 16.0 32
0 ... 25.0 50
0 ... 40.0 80
0 ... 60.0 120
0 ... 100.0 200
0 ... 160.0 320
0 ... 250.0 500
0 ... 400.0 800
0 ... 600.0 1000
Massbilder / Cotes d'encombrement / Dimensions
NSL NSL
H73250g Trafag AG 03/2008

825X.XX.2X17.XX 825X.XX.2X18.XX 825X.XX.2X30.XX 825X.XX.2X24.XX 825X.XX.4X17.XX 825X.XX.4X30.XX
825X.XX.XXXX.01.XX 825X.XX.XXXX.32.XX 825X.XX.XXXX.35.XX

We reserve the right to make alternations as technical progress may warrant.
NSL: Empfohlene Montageposition 825X.XX.XXXX.XX.33 825X.XX.XXXX.XX.34

NSL: Position de montage recommandée
NSL: Recommended mountig position
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 High level DRY = ON Low level WET = ON
GB
LED indication Niveau haut Sec = Passant Niveau bas
TROCKEN = EIN Mouillé = Passant
Oberer Begrenzer NASS = EIN
Indication de Hög nivå TORR = TILL Unterer Begrenzer
F
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
Load switching ac/dc ∆U
<3mA
∆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
orientatie van de vork
Vibrating Fork
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
Wetside temp. -40oC to +150oC
Ambient temp. -40oC to +80oC
(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.)
Max. conductor size 1.5mm2
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
Température liquide. -40oC à +150oC
Température ambiante -40oC à +80oC
(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
Orientable en 4 sens (90/180/270/360o.)
Capacité conducteur 1.5mm2 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
Temp. nasse Seite -40oC bis +150oC
Umgebungstemp. -40oC bis +80oC (50oC bei 150oC nasse Seite)
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°)
Max. Leiterquerschnitt 1,5 mm2
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
Vätsketemp. -40oC till +150oC
Omgivn.temp. -40oC till +80oC (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.
Max area per ledare: 1,5 mm2
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
Temp. Partes húmedas. -40oC a +150oC
Temp. Ambiente. -40oC a +80oC (-50oC a 150oC partes
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.)
Tamaño máx. cables 1.5mm2
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
Vloeistof To 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.)
Max geleiderssectie 1,5mm2
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
Temperatura procesu. -40oC to +150oC
Temperatura otoczenia. -40oC to +80oC
(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.)
Max. rozmiar przewodów 1.5mm2
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
DC
application notes
M18
100308
Typ / Type Nr./No.
SK1-HT125-FS-JM18-PS-VA/PTFE 07061
SK1-HT125-FS-JM18-PO-VA/PTFE 07062
SK1-HT125-FS-JM18-NS-VA/PTFE 07063
SK1-HT125-FS-JM18-NO-VA/PTFE 07064
Mounting [flush / nonflush] [ B / NB ]
Operating distance Sn [mm]
Hysteresis H [%SR]
Frequency of operating cycles f [Hz] 5
Repeat accuracy R [%SR]
Operating temperature range Ta [C°] -30... 125 [-30... 100]LED
Temperature drift [range] [%SR]
Protection class IP 67 / IP 68 - 10 bar
Rated insulation voltage Ui [V] 75 d. c.
Material of housing A: Al-Druckguss; B: V2A; C: PTFE
Utilisation category DC13
Connection Klemmen
Supply voltage range UB Ub [V] 10... 35
No-load supply current Iomax. [mA] 10
Minimum operational current Im [mA]
Operational current Ie [mA] 100
Off-state current Ir [mA] 200
Voltage drop Ud @ Ie [V] 2,7
Time delay before availability tv [ms]
Indicator [UB / Output] −/• LED int.
Short circuit- overload-protection •/•
Reverse polarity protection •
Conformity EMC IEC 60947-5-2 : 2004
EEC-direct.
EMC IEC 61000-4-6 (Testlevel 3V) Functional errors may

occur in partition of working frequency 2.3-19.2 Mhz.
Associated equipment MA-M18/###/10-V2A
Additional functionality
Application
SIE SENSORIK GmbH * Postfach 1766 * 68507 Viernheim / Germany * Phone +49-6204-7058-0 * Fax +49-6204-7058-10 * www.sie-sensorik.de
Subject to change without notice. Errors excepted.
11 Additional Components & Accessories

Zusätzliche Komponenten & Zubehör
11.1 CIP Unit

CIP Einheit
Set of Final Drawings
Zeichnungssatz
Installationsschema
Graphical Symbols
Grafiksymbole
Device List
Geräteliste
Dimensioned Drawing
Aufstellungsplan
Wartungseinheit
Type C06-K10
Diaphragm Pump Unit
Type P200

Customer: Project-/Order-No.: 000001 / 402000001
Location: Project-title: 4530_909510

Devicelist_Cleaning unit compl.
Quotation-No.:
Global Comments: ---
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Date: 01.10.2010 Dept.: Belongs to: ---
Type: --- Corr. Drawing: P402000001-9913-PID101
Repl. for: --- Repl. by: --- Std. checked: --- ---
Explanations:
Priority (A): Procurement (B): Scope of Supply (C):
N = Obligatory M = Must be obtained from Westfalia L = Scope of supply by WS
E = Recommended K = May be obtained from Westfalia S = Supplied by client
P = Possible Z = Supplied by client F = To be removed
U = --- V = --- W = ---
Created Date: 01.10.2010 Checked Date: 28.09.2010 Approved Date: Document No.: Revison: Page:
By: 4530KRA By: 4510gr By: P402000001-9913-DVL003 1/2
Filename: sv010022\WS4530\Kundenaufträge\4530_909510.prj@sv010022\Projekt/Dokumentablage\Basic and Process Engineering\Equipmentlisten\P402000001-9913-DVL003
Customer: Project-/Order-No.: 000001 / 402000001
Location: Project-title: 4530_909510

Devicelist_Cleaning unit compl.
Description Size/Type Comments
ID Quantity Material 1 Material 2 Power Part-No. A B C
Usage Nominal Bore PID Code
Compressed air control assembly C 06-K10

08-7-001 1 Stk ZN-pressure casting --- --- 0018-8303-560 N M L
DN8 / DN10
Vessel for Cleaning Agent max. 60L
10-2-001 1 Stk 1.4404 --- N M L
P200/AAPPP/BNS/VT/ABN/0
Diaphram pump
10-3-001 1 Stk 696 --- --- --- 8078-9200-100 N M L
---
Socket Gate Valve ---
10-7-001 1 Stk 1.4408 --- --- 0018-1410-410 N M L
1’’
Created Date: 01.10.2010 Checked Date: 28.09.2010 Approved Date: Document No.: Revison: Page:
By: 4530KRA By: 4510gr By: P402000001-9913-DVL003 2/2
Filename: sv010022\WS4530\Kundenaufträge\4530_909510.prj@sv010022\Projekt/Dokumentablage\Basic and Process Engineering\Equipmentlisten\P402000001-9913-DVL003
D Einbau- und Bedienungsanleitung
GB Fitting and operating instructions 17-4-1
F Instructions pour le montage et l’entretien
Wartungseinheiten
Filterregler - Nebelöler
Service units
filter regulator – oil-mist lubricator
les groupes de surveillance

détendeur à filtre- lubrificateur
Wartungseinheiten, aus Filter- Air treatment units normally consisting Les groupes de surveillance, composés
regler und Öler bestehend, haben die of filter regulator, and fog lubricator are normalement d'un détendeur à filtre, et
Aufgabe, Druckluft als Betriebsmittel intended for cleaning compressed air for d'un lubrificateur à brouillard d'huile, ont
von flüssigen und festen Bestandteilen workshop purposes from liquid and solid pour fonction d'épurer l'air comprimé
zu reinigen, den Luftdruck zu regeln und contamination, for pressure regulation and servant d'agent moteur en le
die Luft mit feinst vernebeltem Öl zur for providing a fine oil spray for the débarrassant des particules liquideset
Schmierung von Zylindern, Ventilen, lubrication of cylinders, valves, compressed solides, de réguler la pression d'air et
druckluftgesteuerten Werkzeugen und air controlled tools ect. d'imprégner l'air avec un brouillard d'huile
dergleichen zu durchsetzen. In richtiger, When used correctly and in accordance extrêmement fin pour le graissage des
den jeweiligen Betriebsverhältnissen with the respective operating conditions, cylindres, soupapes, outils pneu-
entsprechender Anwendung erhalten they maintain the performance level of matiques, etc.
sie den Leistungsgrad pneumatischer pneumatic plant and increase its service Utilisés de façon adéquate, en fonction
Anlagen und erhöhen deren life. Our special brochures covering air des conditions de service correspon-
Lebensdauer. Eine übersichtliche Dar- treatment units contain the sizes and types dantes, ils contribuent à conserver aux
stellung der einzelnen Typen und with all details in a clearly arranged table installations pneumatiques leur puissance
Größen in unserem Hauptkatalog und thus facilitating selection according to the et à prolonger leur durée de vie. La
die technischen Details in unseren operating requirements. description très claire et les détails
Datenblättern erleichtert die richtige techniques donnés par nos dépliants
Auswahl nach Maßgabe der Betriebs- spéciaux sur les différents types et
ansprüche. dimensions de groupes de surveillance
facilitent un choix adéquat en fonction des
© Riegler 17-4-1
exigences d'exploitation.
Einbau Fitting Montage
In Pfeilrichtung, so nah wie möglich an Sequence (in direction of arrow) in normal Le montage s'effectue normalement
den Verbraucher (max. 10m vor dem cases: filter regulator - fog lubricator; the (dans le sens de la flèche) dans l'ordre
Verbraucher). distance between the air treatment unit and suivant: détendeur à filtre - Lubrifica-
Einbaulage vertikal, bezogen auf die the consumerpoint should be as short as teur à brouillard d'huile, et ce à la plus
Behälter. possible. The units must be mounted faible distance possible du point de
vertically. prélèvement.
04/05 techn.Änderungen vorbehalten 1.1

Filterregler Filter regulator Dètendeur à filtre
Filter Filter Filtre
Druckluft enthält Kondenswasser, Rohr- Compressed air contains water condensate L'air comprimé contient de l'eau de con-
zunder, Rostteilchen, u.ä., die pneu- scale, rust particles etc. which attack densation, des oxydes de tuyauterie, des
matisch gesteuerte und betriebene pneumatically controlled and actuated tools particules de rouille etc. qui attaquent les
Werkzeuge, Druckzylinder, Ventile usw. such as compressed air cylinders, valves outils à commande ou entraînement
angreifen und auf deren Funktion störend etc. and which thus have a disturbing effect pneumatique, vérins, soupapes, etc., et
einwirken. Die Reinigung der Druckluft ist on their function. For this reason the perturbent leur bon fonctionnement. C'est
deshalb eine unerläßliche Notwendigkeit purification of compressed air is an pourquoi l'épuration de l'air comprimé est
und wird durch den Filter bewirkt. Der indispensable necessity and is undertaken une nécessité absolue, et elle est assurée
Reinigungsgrad ist von der Porenweite with the aid of filters. The filtering effect is par le filtre. Le degré d'épuration
(normal 40µ) des Sinterfilters abhängig. dependent on the pore diameter (normally (élimination des éléments solides et
Auf Wunsch können Sinterfilter mit 40µ) of the sintered filter. If required, liquides) dépend du diamètre des pores
geringerer Porenweite eingebaut werden. sintered filters with smaller pore diameter (normalement 40 microns) du filtre fritté.
can be fitted. Sur demande, nous pouvons monter des
filtres à pores de moindre diamètre.
Wartung: Kondenswasser regelmäßig ab- Servicing: Drain off the water condensate Entretien: Purger régulièrement l'eau de
lassen und Sinterfilter, wenn verschmutzt, at regular intervals and clean the sintered condensation et nettoyer le filtre fritté dès
reinigen. filter if it is dirty. qu'il est encrassé.
Ausbau: Behälter abschrauben, Removal: Unscrew the bowl. Dépose: Retirer la cuve,
Prallscheibe vom Sinterfilter lösen, Undo the twist plate from the sintered filter; dévisser l’écrou de fixation du filtre en
Sinterfilter herausnehmen. Sinterfilter in take out the sintered filter. Place the métal fritté et sortir ce dernier, le
Lösungsmittel legen (z.B. Benzin Tri usw.) sintered filter in a solvent (e.G. petrol, tricho remplacer par un filtre neuf. Replacer la
gut durchschwenken und trocknen, dann etc.), agitate well and dry. Replace the filter. cuve. Veiller à ce que le joint O-Ring soit
wieder einbauen. Auf einwandfreie Ensure that the seal is perfectly seated. For en parfait état.
Dichtung achten. cleaning of the plastic bowl, see the next
page.
Druckregler Pressure regulator Manodétendeur
Der Leitungsdruck einer Druckluftanlage The system pressure in a compressed air La pression existant dans la tuyauterie
schwankt entsprechend der Kompres- installation fluxuates according to the size d'une installation à air comprimé varie en
sorgröße (z.B. 6-10 oder 10-16 bar usw.). of the compressor (e.g. 6-10 or 10-16 bar fonction des dimensions compresseur (par
Druckregler reduzieren diesen etc.). Pressure regulators reduce this ex. 6 à 10 ou 10 à 16 bar). Les
schwankenden Leitungsdruck (Vordruck) fluxuating system pressure (upstream pres- manodétendeurs réduisent et stabilisent
auf den gewünschten Arbeitsdruck (Hinter- sure) to the desired working pressure cette pression variable (pression primaire)
© Riegler 17-4-1
druck) und halten diesen konstant. (downstream pressure) and maintain it à la pression de service désirée.
constant.
Für Wartungseinheiten werden Pressure regulators with reverse control are Pour les groupes de surveillance on utilise
Druckregler mit Rücksteuerung ver- used for air treatment units. Pressure normalement des manodétendeurs à
wendet. Druckregler mit Rücksteuerung regulators with reverse control offer the commande en retour, L'avantage de ces
haben den Vorteil, daß der Hinterdruck advantage that the downstream pressure appareils est qu'ils premettent de diminuer
ohne Luftentnahme durch Zurückdrehen can be reduced, without bleeding off air, by la pression sans prélèvement d'air, en
der Regulierschraube vermindert werden turning back the regulating screw. In dévissant la broche de réglage. Les
kann. Ferner werden die Rückstöße, addition, the blow-backs which occure in réactions qui se produisent avec les
welche bei pneumatischen Steuerungen pneumatic controls are vented to commandes pneumatiques, sont
auftreten, durch die Rücksteuerung, atmosphere by the reverse control (which at évacuées en outre dans l'atmosphère par
welche zugleich als Sicherheitsventil be- the same time can also be regarded as a la commande en retour gui fait en même
trachtet werden kann, in die Atmosphäre safety valve) thus protecting the pressure temps fonction de soupape de sûreté, ce
geleitet, wodurch das Manometer ge- gauge. qui a pour effet de protéger le manomètre.
schützt wird.

Druckluftaufbereitung 17-4-1
Druckeinstellung: Handrad ziehen (Regler Pressure setting: Pull the adjusting knob, Réglage de la pression: Tourner
entriegelt), Druckregler durch drehen des or release the lock nut (Regulator ensuite le volant dans le sens des
Handrades auf den gewünschten Druck unlocked) then by tuning the knob adjust aiguilles d’une montre jusqu’à ce que
einstellen, Handrad drücken (Regler the pressure regulator to the desired le manomètre du détendeur indique la
verriegelt). pressure, finally press the adjusting knob, pression de service désirée. Bloquer
or set the lock nut (Regulator locked) down ensuite le volant à l’aide du bouton d’
to fix the unit set at the desired pressure. arrét.
Nebelöler Fog lubricator Lubrificateurs
Die Druckluft wird durch den Nebelöler mit The compressed air is enriched with a fine Grâce au lubrificateur, l'air comprimé
feinem Ölnebel angereichert und bewirkt in oil mist by the fog lubricator so that in this est enrichi d'un fin brouillard d'huile
diesem Zustand eine laufende und zuver- state it thus effects continuous and reliable et, dans cet état, assure un graissage
lässige Schmierung pneumatisch ge- lubrication of the pneumatically controlled constant et sûr des outils, vérins,
steuerter Druckluftwerkzeuge, Zylinder, compressed air tools, cylinders, valves etc. soupapes, etc. à commande
Ventile usw. pneumatique.
Bitte beachten: Mindestbetriebsdruck Please note: Minimum operating pressure Très important: La pression de ser-
0,5 bar. is 0,5 bar. vice minimale est de 0,5 bar.
Dosierung: Die Ölmenge (Tropfen pro Dosage: Set the amount of oil (drops per Dosage: Pendant la marche, régler le
Minute) während des Betriebes an der minute) on the dosaging screw as required débit d'huile (gouttes par minute)
Dosierschraube nach Bedarf einstellen. during operation. The number of drops can suivant besoin à l'aide de la vis de
Tropfenzahl im Schauglas ersichtlich. be seen in the sight-glass. dosage. Le nombre de gouttes peut
être contrôlé à travers le regard
transparent
Öleinfüllung: Einfüllschraube entfernen, Oil filling: Remove the oil filler screw. Remplissage d'huile: Dévisser le
Behälter bis zu Einfüllmarke (ca. 2/3) füllen. Fill the bowl to the upper mark (approx. 2/3 bouchon de remplissage, remplir le
Einfüllschraube gut schließen. Ölnach- full). Firmly replace the filler screw. It is réservoir jusqu'au repère (env. 2/3).
füllung während des Betriebes möglich, possible to replenish the oil during Bien revisser ensuite le bouchon de
die Luftzufuhr braucht nicht abgestellt operation; the air supply need not be shut remplissage. Le remplissage d'huile
werden. off. peut être effectué pendant la marche;
© Riegler 17-4-1
il n'est pas nécessaire de fermer

l'admission d'air.
Ölsorte: HL 25 nach DIN 51524-ISO VG Oil types: 22 - 46 cSt at 40°C. In special Sorte d'huile 22-46 cSt E 40°C .
32. In besonders gelagerten Fällen wende cases refer to the technical lubrication Dans les cas exceptionnels,
man sich an die schmiertechnischen service of the oil companys whose s'adresser aux services techniques de
Dienste der Ölgesellschaften, deren engineers are always available to give free graissage des sociétés pétrolières;
Ingenieure jederzeit unverbindlich und advice on all lubrication problems without leurs ingénieurs sont en tout temps à
kostenlos zur Beratung aller schmier- obligation. votre disposition pour vous conseiller
technischen Fragen zur Verfügung stehen. gratuitement et sans engagement sur
toutes les questions techniques
relatives au graissage.
04/05 techn. Änderungen vorbehalten 1.3

Tropfaufsätze: Für besondere Dome assembly: For special appli-

Fälle sind Tropfaufsätze aus Metall cations you need a dome assembly made
lieferbar. of metal.
Max. Betriebsdruck und Betriebs- Maximum operating pressures and Pression de service et température de
temperatur für Filter-Druckregler-und operating temperatures for pressure re- fonctionnement maxi.pour filtres et
Nebelöler: gulators and fog lubricators: lubrificateurs à brouillard d'huile:
max. Betriebsdruck bar max. operating pressure bar Pression de service maxi. bar
Kunststoffbehälter ohne Plastic bowl, with or without Cuve en matière plastique avec
oder mit Schutzkorb 16 protective cage 16 ou sans grillage de protection 16
Metallmantel 25 Metal casing 25 Cuve métallique 25
_______________________________ ________________________________ ________________________________
Betriebstemperatur °C Operating temperature C° Température de service C°

Kunststoffbehälter 0 bis + 50 Plastic bowl 0 to + 50 Cuve en matière plastique 0 à + 50
Metallmantel 0 bis + 60 Metal casing 0 to + 60 Cuve métallique 0 à + 60
Kunststoffbehälter dürfen nur mit Plastic bowls may only be cleaned Cuves en matière plastique
Wasser, Petroleum oder Waschbenzin using water, petroleum or spirit. Please «Makrolon»:
gereinigt werden. note: Petrol supplied for use in internal Les cuves en matière plastique doivent
Bitte beachten: Tankstellenbenzin ist combustion engines is not cleaning spirit. être nettoyées exclusivement avec de
kein Waschbenzin. l'eau, de l'essence rectifiée ou du
pétrole.
Benzin, Benzol, Aceton, trihaltige Benzine, benzole, acetone, cleaning Ne jemais utiliser de benzène, de
einigungsmittel oder ähnliches darf fluids containing tricho, or similar are l'essence normale ou super, de
keinesfalls zum Reinigen der Behälter under no cirumstances permitted for use l'acétone, de solvants contenant du
verwendet werden. Das Öl welches as cleaning agents for the bowl. The filling trichloréthylène ou d'autres produits
eingefüllt wird, darf mit keinen Flüssig- oil may not be thinned or blended with any analogues.
keiten, welche Weichmacher enthalten, fluid that contains emollients such as
z.B. Alkohol, Glysantin usw. verdünnt alcohol, "Glysantin" (antifreeze) etc.
bzw. vermengt werden.
Für Schäden, die durch Nichtbeachtung No responsibility can be accepted for Il ne faut jemais verser dans les cuves
dieser Vorschrift entstehen, kann keine damage which may result from non- ob- en Makrolon des liquides contenant des
© Riegler 17-4-1
Haftung übernommen werden. servance of these instructions. plastifiants tels que de l'alcool, du
glysantin etc.
Riegler & Co. KG, Schützenstr. 27 - 72574 Bad Urach Telefon (07125) 9497-0 Fax (07125) 949797

P200/PX200 EOM
Engineering
Operation &
Advanced™ Series METAL Pumps Maintenance
Advance your process
LISTED
79
WIL-11080-E-08
REPLACES WIL-11080-E-07
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. P200 Performance Curves
Rubber-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TPE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PTFE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
B. PX200 Performance
Operating Principal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
How to Use this EMS Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Performance Curves
Rubber-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
TPE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
PTFE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
C. Suction Lift Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 6 SUGGESTED INSTALLATION, OPERATION & TROUBLESHOOTING . . . . . . . .20
SECTION 7 ASSEMBLY / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
SECTION 8 EXPLODED VIEW & PARTS LISTING

P200 Rubber/TPE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
P200 PTFE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
PX200 Rubber/TPE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
PX200 PTFE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
SECTION 9 ELASTOMER OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

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, under any circumstance loosen the set
screw located at the adjuster dial of the Pro-Flo X™ pump. If the CAUTION: Do not exceed 82°C (180°F) air inlet temperature for
set screw is loose when the pump is pressurized, it could eject Pro-Flo X™ models.
and cause injury to anyone in the area.
CAUTION: Pumps should be thoroughly flushed before
CAUTION: Do not over-lubricate air supply — excess installing into process lines. FDA and USDA approved pumps
lubrication will reduce pump performance. Pump is pre-lubed. should be cleaned and/or sanitized before being used.
Temperature Limits: CAUTION: Always wear safety glasses when operating pump.
If diaphragm rupture occurs, material being pumped may be
Neoprene –18°C to 93°C 0°F to 200°F forced out air exhaust.
Buna-N –12°C to 82°C 10°F to 180°F
EPDM –51°C to 138°C –60°F to 280°F CAUTION: Before any maintenance or repair is attempted, the
Viton® –40°C to 177°C –40°F to 350°F compressed air line to the pump should be disconnected and all
air pressure allowed to bleed from pump. Disconnect all intake,
Saniflex™ –29°C to 104°C –20°F to 220°F
discharge and air lines. Drain the pump by turning it upside down
Polytetrafluoroethylene (PTFE) and allowing any fluid to flow into a suitable container.
4°C to 104°C 40°F to 220°F
Polyurethane –12°C to 66°C 10°F to 150°F CAUTION: Blow out air line for 10 to 20 seconds before
attaching to pump to make sure all pipeline debris is clear. Use
NOTE: Not all materials are available for all models. Refer to an in-line air filter. A 5µ (micron) air filter is recommended.
Section 2 for material options for your pump. NOTE: When installing PTFE diaphragms, it is important
to tighten outer pistons simultaneously (turning in opposite
NOTE: UL listed configured pumps have the following directions) to ensure tight fit. (See torque specifications in
temperature limits: Section 7.)
UL 79 Buna- -12.2°C (10°F) to 52°C (125°F)
UL 79 PTFE- 4.4°C (40°F) to 52°C (125°F) NOTE: Cast Iron PTFE-fitted pumps come standard from the
factory with expanded PTFE gaskets installed in the diaphragm
CAUTION: Canadian Standards Association (CSA) configured bead of the liquid chamber. Teflon® gaskets cannot be re-used.
pumps should not be used in temperatures lower than 0.0°C to Consult PS-TG for installation instructions during reassembly.
51.6°C (32°F to 125°F). This excludes Pro-Flo® P200 Advanced™ metal pumps.
CAUTION: When choosing pump materials, be sure to check NOTE: Before starting disassembly, mark a line from each liquid
the temperature limits for all wetted components. Example: chamber to its corresponding air chamber. This line will assist in
Viton® has a maximum limit of 177°C (350°F) but polypropylene proper alignment during reassembly.
has a maximum limit of only 79°C (175°F).
CAUTION: Pro-Flo X™ pumps can be used for submersible
CAUTION: Maximum temperature limits are based upon applications, when using the Pro-Flo X™ submersible option.
mechanical stress only. Certain chemicals will significantly Turbo-Flo™ pumps can also be used for submersible applications
reduce maximum safe operating temperatures. Consult when using the Turbo-Flo™ submersible option.
Chemical Resistance Guide (E4) for chemical compatibility and
temperature limits. CAUTION: Tighten all hardware prior to installation.
WARNING: Prevention of static sparking — If static sparking CAUTION: The gas outlet of CSA configured pumps must be
occurs, fire or explosion could result. Pump, valves, and vented to a safe location in accordance with local codes or, in the
containers must be grounded to a proper grounding point when absence of local codes, an industry or nationally recognized code
handling flammable fluids and whenever discharge of static having jurisdiction over the specified installation.
electricity is a hazard.
CAUTION: For U.L. listed pumps, all pipe connections are to be
CAUTION: Canadian Standards Association (CSA) configured made using U.L. classified gasoline-resistant pipe compound.
pumps must be electrically grounded using the grounding
CAUTION: For U.L. listed pumps all installations must conform to
conductor provided. Improper grounding can cause improper
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: For U.L. listed pumps, do not exceed 3.4 bar (50
connected to pipe or tubing to be routed outdoors or other location
psig) air supply pressure.
determined to be equivalent.
CAUTION: Do not exceed 8.6 bar (125 psig) air supply
CAUTION: For U.L. listed pumps, pump is to be grounded
pressure.
using the jam-nut located at the top of the long vertical carriage
CAUTION: Canadian Standards Association (CSA) configured bolt. The ground connection is marked with a tag having the
pumps should not exceed 6.9 bar (100 psig) natural gas supply grounding symbol.
pressure.
Grounding Symbol
WIL-11080-E-08 1 WILDEN PUMP & ENGINEERING, LLC

Section 2
W I L D E N P U M P D E S I G N AT I O N S Y S T E M
P200 & PX200 LEGEND P200 / XXXX X / XXX / XX / X XX / XXXX

ADVANCED™ O-RINGS
METAL MODEL VALVE SEAT SPECIALTY
VALVE BALLS CODE
DIAPHRAGMS (if applicable)
25 mm (1") Pump AIR VALVE
CENTER SECTION
Maximum Flow Rate: WETTED PARTS & OUTER PISTON
212 lpm (56 gpm)
MATERIAL CODES
MODEL DIAPHRAGMS VALVE BALL
P200 = PRO-FLO® BNS = BUNA-N (Red Dot) BN = BUNA-N (Red Dot)
PX200 = PRO-FLO XTM EPS = EPDM (Blue Dot) FS = SANIFLEXTM
FSS = SANIFLEXTM [Hytrel® (Cream)]
WETTED PARTS & OUTER PISTON [Hytrel® (Cream)] EP = EPDM (Blue Dot)
AA = ALUMINUM / ALUMINUM NES = NEOPRENE (Green Dot) NE = NEOPRENE (Green Dot)
SS = STAINLESS STEEL / PUS = POLYURETHANE (Clear) PU = POLYURETHANE (Clear)
STAINLESS STEEL TEU = PTFE w/EPDM TF = PTFE (White)
WW = DUCTILE IRON / BACK-UP (White) VT = VITON® (White Dot)
DUCTILE IRON TNU = PTFE w/NEOPRENE WF = WIL-FLEXTM [Santoprene®
BACK-UP (White) (Orange Dot)]
CENTER SECTION TSU = PTFE w/SANIFLEX™
AA = ALUMINUM BACK-UP (White) VALVE SEAT
PP = POLYPROPYLENE VTS = VITON® (White Dot) A = ALUMINUM
LL = ACETAL WFS = WIL-FLEXTM [Santoprene® M = MILD STEEL
JJ = CONDUCTIVE (Orange Dot)] S = STAINLESS STEEL
POLYPROPYLENE XBS = CONDUCTIVE BUNA-N
(Two Red Dots) VALVE SEAT & MANIFOLD O-RING
AIR VALVE TXU = PTFE w/CONDUCTIVE BN = BUNA-N
BUNA-N BACK-UP FS = SANIFLEXTM
A = ALUMINUM
ESD = BUNA-N [Hytrel® (Cream)]
P = POLYPROPYLENE
L = ACETAL EP = EPDM
J = CONDUCTIVE NE = NEOPRENE
POLYPROPYLENE PU = POLYURETHANE (Brown)
TF = PTFE (White)
VT = VITON®
WF = WIL-FLEXTM (Santoprene®)
SPECIALTY CODES
0014 25 mm (1”) BSPT side-ported inlet and discharge 0677 25 mm (1") NPT center-ported inlet and discharge 0698 19 mm (3/4") BSPT center-ported discharge
0090 25 mm (1”) NPT center-ported inlet and manifold manifold (Pro-Flo "Drop-in")
0391 25 mm (1”) NPT center-ported inlet and discharge 0678 25 mm (1") BSPT center-ported inlet and discharge 0730 25 mm (1") NPT side-ported inlet and discharge
manifold, CSA manifold 0735 19 mm (3/4") NPT center-ported discharge manifold
0392 25 mm (1”) NPT side-ported inlet and discharge 0687 25 mm (1") NPT center-ported inlet and discharge (Turbo-Flo "Drop-in"), Submersible Center Section
manifold, CSA manifold, Submersible Center Section 0736 19 mm (3/4") BSPT center-ported discharge
0492 U.L. Approved, Side-ported (1” inlet and discharge 0688 25 mm (1") BSPT center-ported inlet and discharge manifold (Turbo-Flo "Drop-in"), Submersible Center
manifolds) manifold, Submersible Center Section Section
0493 U.L. Approved, Center Ported NPT, Turbo 0695 19 mm (3/4") NPT center-ported discharge manifold 0737 19 mm (3/4") NPT center-ported discharge manifold
“drop-in” (1” Inlet facing air inlet, 3/4” discharge (Turbo-Flo "Drop-in") (Pro-Flo "Drop-in"), Submersible Center Section
facing exhaust) 0696 19 mm (3/4") BSPT center-ported discharge 0738 19 mm (3/4") BSPT center-ported discharge
0494 U.L. Approved, Center Ported NPT, Pro-Flo manifold (Turbo-Flo "Drop-in") manifold (Pro-Flo "Drop-in"), Submersible Center
“drop-in” (1” inlet facing exhaust, 3/4” discharge 0697 19 mm (3/4") NPT center-ported discharge manifold Section
facing air inlet) (Pro-Flo "Drop-in")
NOTE: The Wilden UL 79 Listed products covered by this manual are PX200 models followed by AA or SS, followed by AA, followed by A, followed by BNS
or TNU, followed by BN or TF, followed by A or S, followed by BN or TF, followed by 0492, 0493, or 0494. 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).
NOTE: MOST ELASTOMERIC MATERIALS USE COLORED DOT FOR IDENTIFICATION

Nordel® and Viton® is a registered trademark of Dupont Dow Elastomers.
WILDEN PUMP & ENGINEERING, LLC 2 WIL-11080-E-08

Section 3
HOW IT WORKS—PUMP
The Wilden diaphragm pump is an air-operated, positive displacement, self-priming pump. These drawings show flow pattern
through the pump upon its initial stroke. It is assumed the pump has no fluid in it prior to its initial stroke.
#,/3%$ /54,%4 /0%. /0%. /54,%4 #,/3%$ #,/3%$ /54,%4 /0%.
" ! " ! " !
/0%. ).,%4 #,/3%$ #,/3%$ ).,%4 /0%. /0%. ).,%4 #,/3%$
FIGURE 1 The air valve directs pressurized FIGURE 2 When the pressurized diaphragm, FIGURE 3 At completion of the stroke,
air to the back side of diaphragm A. The diaphragm A, reaches the limit of its discharge the air valve again redirects air to the
compressed air is applied directly to the stroke, the air valve redirects pressurized back side of diaphragm A, which starts
liquid column separated by elastomeric air to the back side of diaphragm B. The diaphragm B on its suction stroke. As
diaphragms. The diaphragm acts as pressurized air forces diaphragm B away the pump reaches its original starting
a separation membrane between the from the center while pulling diaphragm A point, each diaphragm has gone through
compressed air and liquid, balancing the to the center. Diaphragm B is now on its one suction and one discharge stroke.
load and removing mechanical stress discharge stroke. Diaphragm B forces the This constitutes one complete pumping
from the diaphragm. The compressed inlet valve ball onto its seat due to the cycle. The pump may take several cycles
air moves the diaphragm away from hydraulic forces developed in the liquid to completely prime depending on the
the center of the pump. The opposite chamber and manifold of the pump. These conditions of the application.
diaphragm is pulled in by the shaft same hydraulic forces lift the discharge
connected to the pressurized diaphragm. valve ball off its seat, while the opposite
Diaphragm B is on its suction stroke; air discharge valve ball is forced onto its seat,
behind the diaphragm has been forced forcing fluid to flow through the pump
out to atmosphere through the exhaust discharge. The movement of diaphragm A
port of the pump. The movement of toward the center of the pump creates a
diaphragm B toward the center of the vacuum within liquid chamber A. Atmos-
pump creates a vacuum within chamber B. pheric pressure forces fluid into the inlet
Atmospheric pressure forces fluid into manifold of the pump. The inlet valve ball
the inlet manifold forcing the inlet valve is forced off its seat allowing the fluid being
ball off its seat. Liquid is free to move pumped to fill the liquid chamber.
past the inlet valve ball and fill the liquid
chamber (see shaded area).
HOW IT WORKS—AIR DISTRIBUTION SYSTEM

The Pro-Flo® patented air distribution system incorporates two
-5&&,%2 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
!)2 ).,%4 !)2 6!,6%
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
!)2 6!,6% 30//, of the air valve spool routes the air to the other air chamber.
-5&&,%2 0,!4%
-!). 3(!&4 0),/4 30//, %.$ #!0

Section 4
DIMENSIONAL DRAWINGS
P 20 0 Advan c e d ™ M e t a l — F l a n ge d DIMENSIONS
A 378 14.9
B 69 2.7
C 196 7.7
D 290 11.4
E 343 13.5
F 71 2.8
G 229 9.0
H 71 2.8
J 122 4.8
K 196 7.7
L 208 8.2
M 173 6.8
N 104 4.1
P 127 5.0
R 10 0.4
DIN FLANGE
S 85 DIA. 3.3 DIA.
T 115 DIA. 4.5 DIA.
U 14 DIA. 0.6 DIA.
ANSI FLANGE
S 79 DIA. 3.1 DIA.
T 108 DIA. 4.3 DIA.
U 16 DIA. 0.6 DIA.
P 20 0 Advan c e d ™ M e t a l — T hre a d e d DIMENSIONS

A 361 14.2
B 36 1.4
C 163 6.4
D 254 10.0
E 287 11.3
F 56 2.2
G 287 11.3
H 71 2.8
J 122 4.8
K 160 6.3
L 206 8.1
M 173 6.8
N 104 4.1
P 127 5.0
R 10 0.4

P20 0 Ad va n c e d ™ M e t a l—Ce n te r- Po rte d
DIMENSIONS
A 386 15.2
B 36 1.4
C 163 6.4
D 257 10.1
E 290 11.4
F 56 2.2
G 229 9.0
H 71 2.8
J 122 4.8
K 163 6.4
L 208 8.2
M 173 6.8
N 104 4.1
P 127 5.0
R 10 0.4

Section 4
P X20 0 Adva n c e d ™ Me t a l — F la n ge d DIMENSIONS
A 373 14.7
B 69 2.7
C 195 7.6
D 287 11.3
E 340 13.4
F 71 2.8
G 384 15.1
H 71 2.8
J 140 5.5
K 188 7.4
L 206 8.1
M 173 6.8
N 104 4.1
P 127 5.0
R 10 0.4
DIN FLANGE
S 85 DIA. 3.3 DIA.
T 115 DIA. 4.5 DIA.
U 14 DIA. 0.6 DIA.
ANSI FLANGE
S 79 DIA. 3.1 DIA.
T 108 DIA. 4.3 DIA.
U 16 DIA. 0.6 DIA.
P X20 0 Adva n c e d ™ Me t a l — T h re a d e d DIMENSIONS

A 361 14.2
B 36 1.4
C 163 6.4
D 254 10.0
E 287 11.3
F 56 2.2
G 384 15.1
H 71 2.8
J 140 5.5
K 155 6.1
L 206 8.1
M 173 6.8
N 104 4.1
P 127 5.2
R 10 0.4

PX20 0 Ad va n c e d ™ Me t al—Ce n te r- Po rte d
DIMENSIONS
A 422 16.6
B 36 1.4
C 163 6.4
D 254 10.0
E 287 11.3
F 56 2.2
G 384 15.1
H 71 2.8
J 140 5.5
K 455 6.1
L 206 8.1
M 173 6.8
N 104 4.1
P 127 5.0
R 10 0.4

Section 5A
PERFORMANCE
P200 ADVANCED™ METAL
RUBBER-FITTED
Height ................................. 343 mm (13.5")
Width ...................................378 mm (14.9")
Depth .................................... 229 mm (9.0")
Ship Weight ........ Aluminum 11 kg (24 lbs.)
Ductile Iron 21 kg (47 lbs.)
316 Stainless Steel 23 kg (51 lbs.)
Air Inlet ..................................... 6 mm (1/4")
Inlet ............................................ 25 mm (1")
Outlet ......................................... 25 mm (1")
Suction Lift ........................ 5.4 m Dry (17.6')
9.3 m Wet (30.6')
Displacement Per Stroke .... 0.30 l (0.08 gal.)1
Max. Flow Rate .............. 212 lpm (56 gpm)
Max. Size Solids .................... 6.4 mm (1/4")
1
Displacement per stroke was calculated at
4.8 bar (70 psig) air inlet pressure against a
2 bar (30 psig) head pressure.
Flow rates indicated on chart were determined by pumping water.
against a discharge pressure head of
3.3 bar (48 psig) requires 4.1 bar (60 psig) For optimum life and performance, pumps should be specified so that daily operation
and 34.0 Nm3/h (20 scfm) air consumption. -parameters will fall in the center of the pump performance curve.
(See dot on chart.)
Caution: Do not exceed 8.6 bar (125psig) air supply pressure. Canadian Standards Association
(CSA) configured pumps should not exceed 6.9 bar (100psig) natural gas supply pressure. Please
read all cautions and suggested installation sections before operating any Wilden product.

TPE-FITTED
Height ................................. 343 mm (13.5")
Width ...................................378 mm (14.9")
Depth .................................... 229 mm (9.0")
Air Inlet ..................................... 6 mm (1/4")
Inlet ............................................ 25 mm (1")
Outlet ......................................... 25 mm (1")
Suction Lift ....................... 4.1 m Dry (13.6')
9.3 m Wet (30.6')
1
(See dot on chart.)

PERFORMANCE
PTFE-FITTED
Height ................................. 343 mm (13.5")
Width ...................................378 mm (14.9")
Depth .................................... 229 mm (9.0")
Air Inlet ..................................... 6 mm (1/4")
Inlet ............................................ 25 mm (1")
Outlet ......................................... 25 mm (1")
Suction Lift ........................ 3.5 m Dry (11.4')
9.3 m Wet (30.6')
1
(See dot on chart.)

PX200
M E T A L
PX200 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 12 PX200 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.
PX200 Performance 13 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 system's 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 14 PX200 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
PX200 Performance 15 WILDEN PUMP & ENGINEERING, LLC

PX200 METAL RUBBER-FITTED
WILDEN PUMP & ENGINEERING, LLC

PERFORMANCE
16
TECHNICAL DATA EXAMPLE
The Efficiency Management System (EMS)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 340 mm (13.4”) A PX200 metal, Rubber-fitted pump operating at EMS setting 4,
can be used to optimize the performance of
Width. . . . . . . . . . . . . . . . . . . . . . . . . . . 378 mm (14.7”) achieved a flow rate of 87 lpm (23 gpm) using 49 Nm3/h (29 scfm)
your Wilden pump for specific applications. of air when run at 5.5 bar (80 psig) air inlet pressure and 4.1 bar (60
Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 mm (9.6”) The pump is delivered with the EMS adjusted
Ship Weight . . . . . . . . . . . . . Aluminum 15 kg (34 lbs.) psig) discharge pressure (See dot on performance curve).
to setting 4, which allows maximum flow.
Ductile Iron 26 kg (57 lbs.) The end user did not require that much flow and wanted to reduce
316 Stainless Steel 28 kg (61 lbs.) The EMS curve allows the pump user to deter- air consumption at his facility. He determined that EMS setting 3
Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (1/2”) mine flow and air consumption at each EMS would meet his needs. At 4.1 bar (60 psig) discharge pressure and
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 mm (1”) setting. For any EMS setting and discharge EMS setting 3, the flow “X factor” is 0.86 and the air “X factor” is
Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 mm (1”) pressure, the “X factor” is used as a multi- 0.74 (see dots on EMS curve).
Suction Lift . . . . . . . . . . . . . . . . . . . . . 5.9 m Dry (19.3’) plier with the original values from the setting Multiplying the original setting 4 values by the “X factors” provides
9.0 m Wet (29.5’) 4 performance curve to calculate the actual the setting 3 flow rate of 75 lpm (20 gpm) and an air consumption of
Disp. Per Stroke. . . . . . . . . . . . . . . . . 0.30 l (0.08 gal.)1 flow and air consumption values for that spe- 36 Nm3/h (21 scfm). The flow rate was reduced by 14% while the
Max. Flow Rate . . . . . . . . . . . . . .212.0 lpm (56.0 gpm) cific EMS setting. Note: you can interpolate air consumption was reduced by 26%, thus providing increased
Max. Size Solids . . . . . . . . . . . . . . . . . . . 6.4 mm (1/4”) between the setting curves for operation at efficiency.
1Displacement per stroke was calculated at 4.8 bar (70 psig) intermediate EMS settings. For a detailed example for how to set your EMS, see beginning of perfor-
air inlet pressure against a 2 bar (30 psig)head pressure. mance curve section.
Caution: Do not exceed 8.6 bar (125psig) air supply pressure. Canadian
Standards Association (CSA) configured pumps should not exceed 6.9
The Efficiency Management System (EMS) can be used to optimize the performance of your Wilden pump for bar (100psig) natural gas supply pressure. Please read all cautions and
PX200 Performance
specific applications. The pump is delivered with the EMS adjusted to setting 4, which allows maximum flow. suggested installation sections before operating any Wilden product.
PX200 METAL TPE-FITTED
PX200 Performance
PERFORMANCE
17
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 340 mm (13.4”) A PX200 metal, TPE-fitted pump operating at EMS setting 4,
Width. . . . . . . . . . . . . . . . . . . . . . . . . . . 378 mm (14.7”) achieved a flow rate of 142 lpm (38 gpm) using 49 Nm3/h (29 scfm)
Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 mm (9.6”) The pump is delivered with the EMS adjusted
Ship Weight . . . . . . . . . . . . . Aluminum 15 kg (34 lbs.) psig) discharge pressure (See dot on performance curve).
Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (1/2”) mine flow and air consumption at each EMS would meet his needs. At 1.4 bar (20 psig) discharge pressure and
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 mm (1”) setting. For any EMS setting and discharge EMS setting 1, the flow “X factor” is 0.18 and the air “X factor” is
Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 mm (1”) pressure, the “X factor” is used as a multi- 0.07 (see dots on EMS curve).
Suction Lift . . . . . . . . . . . . . . . . . . . . . 5.5 m Dry (18.2’) plier with the original values from the setting Multiplying the original setting 4 values by the “X factors” provides
9.0 m Wet (29.5’) 4 performance curve to calculate the actual the setting 1 flow rate of 26 lpm (7 gpm) and an air consumption
Disp. Per Stroke. . . . . . . . . . . . . . . . . 0.34 l (0.09 gal.)1 flow and air consumption values for that spe- of 3 Nm3/h (2 scfm). The flow rate was reduced by 82% while the
Max. Flow Rate . . . . . . . . . . . . . .212.0 lpm (56.0 gpm) cific EMS setting. Note: you can interpolate air consumption was reduced by 93%, thus providing increased
Max. Size Solids . . . . . . . . . . . . . . . . . . . 6.4 mm (1/4”) between the setting curves for operation at efficiency.
Displacement per stroke was calculated at 4.8 bar (70 psig) intermediate EMS settings. For a detailed example for how to set your EMS, see beginning of perfor-
air inlet pressure against a 2 bar (30 psig)head pressure mance curve section.
Standards Association (CSA) configured pumps should not exceed 6.9
The Efficiency Management System (EMS) can be used to optimize the performance of your Wilden pump for bar (100psig) natural gas supply pressure. Please read all cautions and

specific applications. The pump is delivered with the EMS adjusted to setting 4, which allows maximum flow. suggested installation sections before operating any Wilden product.
PX200 METAL PTFE-FITTED

PERFORMANCE
18
Height . . . . . . . . . . . . . . . . . . . . . . . . . .340 mm (13.4”) A PX200 metal, PTFE-fitted pump operating at EMS setting 4,
Width. . . . . . . . . . . . . . . . . . . . . . . . . . .378 mm (14.7”) achieved a flow rate of 129 lpm (34 gpm) using 75 Nm3/h (44 scfm)
Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . .244 mm (9.6”) The pump is delivered with the EMS adjusted
Ship Weight . . . . . . . . . . . . Aluminum 15 kg (34 lbs.) psig) discharge pressure (See dot on performance curve).
Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (1/2”) mine flow and air consumption at each EMS would meet his needs. At 0.7 bar (10 psig) discharge pressure and
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 mm (1”) setting. For any EMS setting and discharge EMS setting 2, the flow “X factor” is 0.63 and the air “X factor” is
Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 mm (1”) pressure, the “X factor” is used as a multi- 0.36 (see dots on EMS curve).
Suction Lift . . . . . . . . . . . . . . . . . . . . .4.3 m Dry (14.2’) plier with the original values from the setting Multiplying the original setting 4 values by the “X factors” provides
9.0 m Wet (29.5’) 4 performance curve to calculate the actual the setting 2 flow rate of 81 lpm (21 gpm) and an air consumption of
Disp. Per Stroke. . . . . . . . . . . . . . . . 0.23 l (0.06 gal.)1 flow and air consumption values for that spe- 27 Nm3/h (16 scfm). The flow rate was reduced by 37% while the
Max. Flow Rate . . . . . . . . . . . . .185.4 lpm (49.0 gpm) cific EMS setting. Note: you can interpolate air consumption was reduced by 64%, thus providing increased
Max. Size Solids . . . . . . . . . . . . . . . . . . 6.4 mm (1/4”) between the setting curves for operation at efficiency.
1
Displacement per stroke was calculated at 4.8 bar (70 psig) intermediate EMS settings. For a detailed example for how to set your EMS, see beginning of perfor-
air inlet pressure against a 2 bar (30 psig)head pressure. mance curve section.
The Efficiency Management System (EMS) can be used to optimize the performance of your Wilden pump for Standards Association (CSA) configured pumps should not exceed 6.9
bar (100psig) natural gas supply pressure. Please read all cautions and
specific applications. The pump is delivered with the EMS adjusted to setting 4, which allows maximum flow.
PX200 Performance
suggested installation sections before operating any Wilden product.
Section 5C
SUCTION LIFT CURVE
P 2 0 0 ADVANCED™
ME TA L SUC T ION L IF T
CAPABILIT Y
SUCTION LIFT CURVE
PX 2 0 0 ADVANCED™
ME TA L SUC T ION L IF T
CAPABILIT Y

Section 6
SUGGES T ED INS TA L L AT ION
Wilden pumps are designed to meet the performance requirements ELEVATION: Selecting a site that is well within the pump’s
of even the most demanding pumping applications. They have dynamic lift capability will assure that loss-of-prime issues will be
been designed and manufactured to the highest standards and are eliminated. In addition, pump efficiency can be adversely affected
available in a variety of liquid path materials to meet your chemical if proper attention is not given to site location.
resistance needs. Refer to the performance section of this manual
PIPING: Final determination of the pump site should not be made
for an in-depth analysis of the performance characteristics of your
until the piping challenges of each possible location have been
pump. Wilden offers the widest variety of elastomer options in the
evaluated. The impact of current and future installations should be
industry to satisfy temperature, chemical compatibility, abrasion
considered ahead of time to make sure that inadvertent restrictions
resistance and flex concerns.
are not created for any remaining sites.
The suction pipe size should be at least the equivalent or larger
For U.L. listed pumps, all installation must conform with NFPA 30,
than the diameter size of the suction inlet on your Wilden
NFPA 30A, and other applicable codes. All pipe connections are to
pump. The suction hose must be non-collapsible, reinforced
be made using U.L. classified gasoline-resistant pipe compound.
type as these pumps are capable of pulling a high vacuum.
Exhaust port is to be connected to pipe or tubing to be routed
Discharge piping should also be the equivalent or larger than
outdoors or other location determined to be equivalent.
the diameter of the pump discharge which will help reduce
friction losses. It is critical that all fittings and connections The best choice possible will be a site involving the shortest and
are airtight or a reduction or loss of pump suction capability straightest hook-up of suction and discharge piping. Unnecessary
will result. elbows, bends, and fittings should be avoided. Pipe sizes should
be selected to keep friction losses within practical limits. All piping
INSTALLATION: Months of careful planning, study, and selection
should be supported independently of the pump. In addition, the
efforts can result in unsatisfactory pump performance if installation
piping should be aligned to avoid placing stress on the pump
details are left to chance.
fittings.
Premature failure and long term dissatisfaction can be avoided if
Flexible hose can be installed to aid in absorbing the forces created
reasonable care is exercised throughout the installation process.
by the natural reciprocating action of the pump. If the pump is
LOCATION: Noise, safety, and other logistical factors usually to be bolted down to a solid location, a mounting pad placed
dictate where equipment will be situated on the production floor. between the pump and the foundation will assist in minimizing
Multiple installations with conflicting requirements can result pump vibration. Flexible connections between the pump and
in congestion of utility areas, leaving few choices for additional rigid piping will also assist in minimizing pump vibration. If quick-
pumps. closing valves are installed at any point in the discharge system,
or if pulsation within a system becomes a problem, a surge
Within the framework of these and other existing conditions,
suppressor (SD Equalizer®) should be installed to protect the
every pump should be located in such a way that six key factors
pump, piping and gauges from surges and water hammer.
are balanced against each other to maximum advantage.
If the pump is to be used in a self-priming application, make sure
ACCESS: First of all, the location should be accessible. If it’s easy
that all connections are airtight and that the suction lift is within
to reach the pump, maintenance personnel will have an easier
the model’s ability. Note: Materials of construction and elastomer
time carrying out routine inspections and adjustments. Should
material have an effect on suction lift parameters. Please refer to
major repairs become necessary, ease of access can play a key
the performance section for specifics.
role in speeding the repair process and reducing total downtime.
When pumps are installed in applications involving flooded
AIR SUPPLY: Every pump location should have an air line large
suction or suction head pressures, a gate valve should be installed
enough to supply the volume of air necessary to achieve the
in the suction line to permit closing of the line for pump service.
desired pumping rate. Use air pressure up to a maximum of 8.6
bar (125 psig) depending on pumping requirements. Pumps in service with a positive suction head are most efficient
when inlet pressure is limited to 0.5–0.7 bar (7–10 psig). Premature
For best results, the pumps should use a 5µ (micron) air filter,
diaphragm failure may occur if positive suction is 0.7 bar (10 psig)
needle valve and regulator. The use of an air filter before the pump
and higher.
will ensure that the majority of any pipeline contaminants will be
eliminated. SUBMERSIBLE APPLICATIONS: Pro-Flo X™ pumps can be used for
submersible applications, when using the Pro-Flo X™ submersible
NOTE: Canadian Standards Association (CSA) configured pumps
option. Turbo-Flo™ pumps can also be used for submersible
should not exceed 6.9 bar (100psig) natural gas supply pressure.
applications when using the Turbo-Flo™ submersible option.
Only CSA configured pumps should be operated using natural
gas. NOTE: Pro-Flo® and Accu-Flo™ pumps are not submersible.
SOLENOID OPERATION: When operation is controlled by a ALL WILDEN PUMPS ARE CAPABLE OF PASSING SOLIDS. A
solenoid valve in the air line, three-way valves should be used. STRAINER SHOULD BE USED ON THE PUMP INTAKE TO ENSURE
This valve allows trapped air between the valve and the pump to THAT THE PUMP'S RATED SOLIDS CAPACITY IS NOT EXCEEDED.
bleed off which improves pump performance. Pumping volume
CAUTION: DO NOT EXCEED 8.6 BAR (125 PSIG) AIR SUPPLY
can be estimated by counting the number of strokes per minute
PRESSURE.
and then multiplying the figure by the displacement per stroke.
CAUTION: CANDAIN STANDARDS ASSOCIATION (CSA)
MUFFLER: Sound levels are reduced below OSHA specifications
CONFIGURED PUMPS SHOULD NOT EXCEED 6.9 BAR (100PSIG)
using the standard Wilden muffler. Other mufflers can be
NATURAL GAS SUPPLY PRESSURE.
used to further reduce sound levels, but they usually reduce
pump performance. CAUTION: FOR U.L. LISTED PUMPS, DO NOT EXCEED 3.4 BAR
(50 PSIG) AIR SUPPLY PRESSURE.

S U G G E S T E D I N S TA L L AT I O N
This illustration is a generic GAUGE

representation of an air-operated (OPTIONAL)
double-diaphragm pump. EQUALIZER SHUT OFF
SURGE DAMPENER VALVE
(OPTIONAL)
DISCHARGE
FLEXIBLE
CONNECTION
MUFFLER
FLEXIBLE
CONNECTION
SUCTION NEEDLE VALVE
COMBINATION
FILTER & REGULATOR
AIR SHUT OFF VALVE
FOOTPAD
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: The Pro-Flo® and Pro-Flo X™ pumps are situation and can be restarted by reducing the fluid
pre-lubricated, and do not require in-line lubrication. discharge pressure or increasing the air inlet pressure.
Additional lubrication will not damage the pump, The Pro-Flo® and Pro-Flo X™ pumps run solely on
however if the pump is heavily lubricated by an compressed air and do not generate heat, therefore
external source, the pump’s internal lubrication may your process fluid temperature will not be affected.
be washed away. If the pump is then moved to a non-
MAINTENANCE AND INSPECTIONS: Since each
lubricated location, it may need to be disassembled
application is unique, maintenance schedules may be
and re-lubricated as described in the ASSEMBLY/
different for every pump. Frequency of use, line pressure,
DISASSEMBLY INSTRUCTIONS.
viscosity and abrasiveness of process fluid all affect
Pump discharge rate can be controlled by limiting the the parts life of a Wilden pump. Periodic inspections
volume and/or pressure of the air supply to the pump. A have been found to offer the best means for preventing
regulator is used to control air pressure while a needle unscheduled pump downtime. Personnel familiar with
valve is used to control volume. Pump discharge rate the pump’s construction and service should be informed
can also be controlled by throttling the pump discharge of any abnormalities that are detected during operation.
by partially closing a valve in the discharge line of the
pump. This action increases friction loss which reduces RECORDS: When service is required, a record should be
flow rate. (See Section 5.) This is useful when the need made of all necessary repairs and replacements. Over
exists to control the pump from a remote location. a period of time, such records can become a valuable
When the pump discharge pressure equals or exceeds tool for predicting and preventing future maintenance
the air supply pressure, the pump will stop; no bypass problems and unscheduled downtime. In addition,
or pressure relief valve is needed, and pump damage accurate records make it possible to identify pumps
will not occur. The pump has reached a “deadhead” that are poorly suited to their applications.
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
To o l s R e q u i r e d : 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
• 13 mm (1/2") Box pump. Disconnect all intake, discharge, and air lines. Drain the pump by turning it
Wrench upside down and allowing any fluid to flow into a suitable container. Be aware of
• 2 – 25 mm (1") Sockets any hazardous effects of contact with your process fluid.
or Adjustable Wrench NOTE: The model used for these instructions incorporates rubber diaphragms and
• Adjustable Wrench balls. Models with PTFE diaphragms and balls are the same except where noted.
• Vise equipped with

soft jaws (such as
plywood, plastic
or other suitable
material)
Step 1 Step 2 Step 3

Please note alignment marks on Using a 13 mm (1/2") wrench, loosen Remove the discharge manifold to
center section. Use to properly align the discharge manifold from the expose the valve balls, valve seats
liquid chamber to center section. liquid chambers. and valve seat o-rings.

P U M P D I S A S S E M B LY

Remove the discharge valve Using a 13 mm (1/2") wrench, Remove the inlet valve balls, seats
balls, seats and valve seat remove the inlet manifold. and valve seat o-rings from the
o-rings from the discharge manifold liquid chamber and inlet manifold,
and liquid chamber, inspect for inspect for nicks, gouges, chemical
nicks, gouges, chemical attack or attack or abrasive wear.
abrasive wear. Note: Replace worn
parts with genuine Wilden part for
reliable performance.

Using a 13 mm (1/2") wrench, The liquid chamber should be Using two adjustable wrenches
remove the liquid chambers from removed to expose the diaphragm or 25 mm (1”) sockets, remove
the center section. and outer piston. Rotate center diaphragm assembly from center
section and remove the opposite section assembly.
liquid chamber.

P U M P D I S A S S E M B LY

After loosening and removing To remove the remaining diaphragm Inspect diaphragms, outer and
the outer piston the diaphragm assembly from the shaft, secure inner pistons for signs of wear.
assembly can be disassembled. shaft with soft jaws (a vise fitted with Replace with genuine Wilden parts
plywood or other suitable material) to if necessary.
ensure shaft is not nicked, scratched,
or gouged. Using an adjustable
wrench, remove diaphragm assembly
from shaft. Inspect all parts for wear
and replace with genuine Wilden
parts if necessary.
GROUNDING STRAP FOR CSA PX200 PUMPS
Canadian Standards Association (CSA) configured pumps must be

electrically grounded using the grounding strap provided (figure 1).
Improper grounding can cause improper and dangerous operation. To
properly attach the grounding strap to a CSA configured PX200 pump, first
position the grounding strap eyelet over the one longer manifold bolt on
the inlet manifold. Then secure it using the 5/16-18 nut included. This is
done to avoid loosening any of the wetted path components and possibly
creating a leak. Grounding the pump must be done in accordance with
local codes, or in the absence of local codes, an industry or nationally
recognized code having jurisdiction over the specified installation.

A I R VA LV E D I S A S S E M B LY
To o l s R e q u i r e d : 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
• 5 mm (3⁄16") Allen pump. Disconnect all intake, discharge, and air lines. Drain the pump by turning it
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 The Wilden P200 Advanced™ metal pump uses the revolutionary Pro-Flo® air
distribution system. The PX200 Advanced™ metal pump uses the Pro-Flo X™ air
distribution system. A 6 mm (1⁄4") air inlet connects the air supply to the center section.
Proprietary composite seals reduce the coefficient of friction and allow the P200 to
run lube-free. Constructed of polypropylene, the Pro-Flo® air distribution system is
designed to perform in on/off, non-freezing, non-stalling, tough duty applications.

Loosen the air valve bolts utilizing Remove muffler plate and air valve Lift away air valve assembly
a 5 mm (3⁄16") Allen wrench. bolts from air valve assembly and remove air valve gasket for
exposing muffler gasket for inspec- inspection. Replace if necessary.
tion. Replace if necessary.


Remove air valve end cap to expose Remove air valve spool from air Remove pilot spool sleeve retaining
air valve spool by simply lifting up valve body by threading one air snap ring on both sides of center
on end cap once air valve bolts are valve bolt into the end of the spool section with snap ring pliers.
and gently sliding the spool out of
removed. 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.
Step 7 Step 8
Remove pilot spool sleeve from With o-ring pick, gently remove the o-ring from the opposite side of the
center section. “center hole cut” on the spool. Gently remove the pilot spool from sleeve
and inspect for nicks or gouges and other signs of wear. Replace pilot
sleeve assembly or outer sleeve o-rings if necessary. During re-assembly
never insert the pilot spool into the sleeve with the “center cut” side first,
this end incorporates the urethane o-ring and will be damaged as it slides
over the ports cut in the sleeve.
NOTE: Seals should not be removed from pilot spool.

Step 9
Check center section Glyd™ rings
for signs of wear. If necessary,
remove Glyd™ rings with o-ring
pick and replace.
Elastomer Kits
Your Solutions — Wrapped Up
Program Details:
• Elastomer & ADS Repair Kits
• All Sizes Available
• PTFE, Rubber & TPE Elastomers
• One Part Number Simplifies Inventory
• Eliminates Order Errors
• Reduces Re-Build Time
• Rejuvenates Your Pump
NOTE: See Section 9.

R E A S S E M B LY H I N T S & T I P S
ASSEMBLY: SHAFT SEAL INSTALLATION:
Upon performing applicable maintenance to the air PRE-INSTALLATION
distribution system, the pump can now be reassembled. • Once all of the old seals have been removed, the
Please refer to the disassembly instructions for photos inside of the bushing should be cleaned to ensure no
and parts placement. To reassemble the pump, follow debris is left that may cause premature damage to the
the disassembly instructions in reverse order. The air new seals.
distribution system needs to be assembled first, then
the diaphragms and finally the wetted path. Please find INSTALLATION
the applicable torque specifications on this page. The The following tools can be used to aid in the installation
following tips will assist in the assembly process. of the new seals:
• Lubricate air valve bore, center section shaft and pilot Needle Nose Pliers
spool bore with NLGI grade 2 white EP bearing grease Phillips Screwdriver
or equivalent. Electrical Tape
• Clean the inside of the center section shaft bore to • Wrap electrical tape around each leg of the needle
ensure no damage is done to new shaft seals. nose pliers (heat shrink tubing may also be used). This
• A small amount NLGI grade 2 white EP bearing grease is done to prevent damaging the inside surface of the
can be applied to the muffler and air valve gaskets to new seal.
locate gaskets during assembly. • With a new seal in hand, place the two legs of the needle
• Make sure that the exhaust port on the muffler plate nose pliers inside the seal ring. (See Figure A.)
is centered between the two exhaust ports on the • Open the pliers as wide as the seal diameter will allow,
center section. then with two fingers pull down on the top portion of
• Stainless bolts should be lubed to reduce the possibility the seal to form kidney bean shape. (See Figure B.)
of seizing during tightening. • Lightly clamp the pliers together to hold the seal into
the kidney shape. Be sure to pull the seal into as tight
PRO-FLO® MAXIMUM TORQUE of a kidney shape as possible, this will allow the seal to
SPECIFICATIONS travel down the bushing bore easier.
Description of Part Torque • With the seal clamped in the pliers, insert the seal into
Air Valve 3.1 N•m (27 in-lbs) the bushing bore and position the bottom of the seal
Outer Pistons, All Diaphragms 40.7 N•m (30 ft-lbs) into the correct groove. Once the bottom of the seal is
Top and Bottom Manifold 8.5 N•m (75 in-lbs) seated in the groove, release the clamp pressure on the
Liquid Chamber to Center Section 8.5 N•m (75 in-lbs) pliers. This will allow the seal to partially snap back to
its original shape.
• After the pliers are removed, you will notice a slight
PRO-FLO X™ MAXIMUM TORQUE bump in the seal shape. Before the seal can be properly
SPECIFICATIONS resized, the bump in the seal should be removed as
Description of Part Torque much as possible. This can be done with either the
Air Valve 11.3 N•m (100 in-lbs) Phillips screwdriver or your finger. With either the side
Dial Set Screw 11.3 N•m (100 in-lbs)
of the screwdriver or your finger, apply light pressure
to the peak of the bump. This pressure will cause the
Outer Pistons, All diaphragms 47.1 N•m (30 ft-lbs)
bump to be almost completely eliminated.
Top and Bottom Manifold 8.5 N•m (75 in-lbs) • Lubricate the edge of the shaft with NLGI grade 2 white
Liquid Chamber to Center Section 8.5 N•m (75 in-lbs) EP bearing grease.
• Slowly insert the center shaft with a rotating motion.
This will complete the resizing of the seal.
• Perform these steps for the remaining seals.
Figure A Figure B NEEDLE NOSE
PLIERS
SHAFT SEAL
TAPE
SHAFT SEAL
TAPE
Section 8 exploded view & parts listing
Section 8
E XPLODED VIE W & PARTS LISTING
P200 ADVANCED METAL Rubber/ TPE-Fitted EXPLODED VIEW
10
4
9
5
6 13
7
12
8
11
1 3
2
27
28
26
14
15
16 20
17 18 21
19 22
23
24 27
28
26
25
29
28
27
ALL CIRCLED PART IDENTIFIERS ARE INCLUDED IN REPAIR KITS (see section 9).
P200 ADVANCED METAL Rubber/ TPE-Fitted PA R T S L I S T I N G
P200/AAPPP P200/WSPPP P200/SSPPP

No. Description Qty. P/N P/N P/N
1 Pro-Flo® Air Valve Assembly1 1 01-2010-20 01-2010-20 01-2010-20
2 End Cap 1 01-2332-20 01-2332-20 01-2332-20
3 End Cap O-ring 1 01-2395-52 01-2395-52 01-2395-52
4 Air Valve Gasket 1 01-2615-52 01-2615-52 01-2615-52
5 Muffler Plate Gasket 1 01-3505-52 01-3505-52 01-3505-52
6 Muffler Plate 1 01-3181-20 01-3181-20 01-3181-20
7 Screw, SHC, 1/4"-20 x 3" 4 01-6001-03 01-6001-03 01-6001-03
8 Muffler 1 02-3510-99 02-3510-99 02-3510-99
9 Center Section 1 02-3142-20 02-3142-20 02-3142-20
10 Reducer Bushing 1 01-6950-20 01-6950-20 01-6950-20
11 Removable Pilot Sleeve Assy. 1 02-3880-99 02-3880-99 02-3880-99
12 Pilot Spool Retaining O-ring 2 04-2650-49-700 04-2650-49-700 04-2650-49-700
13 Shaft Seal 2 02-3210-55-225 02-3210-55-225 02-3210-55-225
14 Retaining Snap Ring 2 00-2650-03 00-2650-03 00-2650-03
15 Shaft 1 02-3810-03 02-3810-03 02-3810-03
16 Disc Spring 2 02-6802-08 02-6802-08 02-6802-08
17 Inner Piston 2 02-3701-01 02-3701-01 02-3701-01
18 Diaphragm 2 * * *
19 Outer Piston 2 02-4550-01 02-4550-03 02-4550-03
20 Valve Ball 4 * * *
21 Manifold O-ring 4 * * *
22 Valve Seat 4 02-1125-01 02-1125-08 02-1125-03
23 Valve Seat O-ring 4 * * *
24 Liquid Chamber 2 02-5015-01 02-5015-02 02-5015-03
25 Inlet Manifold, ANSI Flange 1 02-5090-01 02-5090-02 02-5090-03
Inlet Manifold, DIN Flange 1 02-5091-01 02-5091-02 02-5091-03
Inlet Manifold, Side Ported, 1" NPT 1 02-5095-01 02-5095-02 02-5095-03
Inlet Manifold, Side Ported, 1" BSPT 1 02-5096-01 02-5096-02 02-5096-03
Inlet Manifold, Center Ported, 1" NPT 1 02-5095-01-677 02-5095-02-677 02-5095-03-677
Inlet Manifold, Center Ported, 1" BSPT 1 02-5096-01-678 02-5096-02-678 02-5096-03-678
26 Discharge Manifold, ANSI Flange 1 02-5030-01 02-5030-02 02-5030-03
Discharge Manifold, DIN Flange 1 02-5031-01 02-5031-02 02-5031-03
Discharge Manifold, Side Ported, 1" NPT 1 02-5035-01 02-5035-02 02-5035-03
Discharge Manifold, Side Ported, 1" BSPT 1 02-5036-01 02-5036-02 02-5036-03
Discharge Manifold, Center Ported, 3/4" NPT 1 02-5035-01-697 02-5035-02-697 02-5035-03-697
Discharge Manifold, Center Ported, 3/4" BSPT 1 02-5036-01-698 02-5036-02-698 02-5036-03-698
Discharge Manifold, Center Ported, 1" NPT 1 02-5035-01-677 02-5035-02-677 02-5035-03-677
Discharge Manifold, Center Ported, 1" BSPT 1 02-5036-01-678 02-5036-02-678 02-5036-03-678
27 Screw, HHC, 5/16"-18 x 1" 32 08-6180-03-42 08-6180-03-42 08-6180-03-42
28 Washer, 5/16" 32 02-6731-03 02-6731-03 02-6731-03
29 Pipe Plug, 1" NPT 2 02-7010-01 02-7010-02 02-7010-03
Pipe Plug, 1" BSP 2 02-7011-01 02-7011-02 02-7011-03
* Refer to Elastomer Options in Section 9.
1

P200 ADVANCED METAL PTFE-Fitted EXPLODED VIEW
10
4
9
5
6 13
7
12
8
11
1 3
2
28
29
27
14
15 21
16
17 18
19 22
23
24
20
28
25
29
27
26
30
29
28
P200 ADVANCED METAL PTFE-Fitted PA R T S L I S T I N G
P200/AAPPP P200/WSPPP P200/SSPPP

No. Description Qty. P/N P/N P/N
1 Pro-Flo® Air Valve Assembly1 1 01-2010-20 01-2010-20 01-2010-20
2 End Cap 1 01-2332-20 01-2332-20 01-2332-20
3 End Cap O-ring 1 01-2395-52 01-2395-52 01-2395-52
4 Air Valve Gasket 1 01-2615-52 01-2615-52 01-2615-52
5 Muffler Plate Gasket 1 01-3505-52 01-3505-52 01-3505-52
6 Muffler Plate 1 01-3181-20 01-3181-20 01-3181-20
7 Screw, SHC, 1/4"-20 x 3" 4 01-6001-03 01-6001-03 01-6001-03
8 Muffler 1 02-3510-99 02-3510-99 02-3510-99
9 Center Section 1 02-3142-20 02-3142-20 02-3142-20
10 Reducer Bushing 1 01-6950-20 01-6950-20 01-6950-20
11 Removable Pilot Sleeve Assy. 1 02-3880-99 02-3880-99 02-3880-99
12 Pilot Spool Retaining O-ring 2 04-2650-49-700 04-2650-49-700 04-2650-49-700
13 Shaft Seal 2 02-3210-55-225 02-3210-55-225 02-3210-55-225
14 Retaining Snap Ring 2 00-2650-03 00-2650-03 00-2650-03
15 Shaft 1 02-3840-03 02-3840-03 02-3840-03
16 Disc Spring 2 02-6802-08 02-6802-08 02-6802-08
17 Inner Piston 2 02-3751-01 02-3751-01 02-3751-01
18 Back-up Diaphragm 2 02-1060-56 02-1060-56 02-1060-56
19 Diaphragm 2 02-1010-55 02-1010-55 02-1010-55
20 Outer Piston 2 02-4601-01 02-4600-03 02-4600-03
21 Valve Ball 4 02-1085-55 02-1085-55 02-1085-55
22 Manifold O-ring 4 70-1280-55 70-1280-55 70-1280-55
23 Valve Seat 4 02-1125-01 02-1125-08 02-1125-03
24 Valve Seat O-ring 4 02-1205-55 02-1205-55 02-1205-55
25 Liquid Chamber 2 02-5015-01 02-5015-02 02-5015-03
28 Screw, HHC, 5/16"-18 x 1" 32 08-6180-03-42 08-6180-03-42 08-6180-03-42
29 Washer, 5/16" 32 02-6731-03 02-6731-03 02-6731-03
30 Pipe Plug, 1" NPT 2 02-7010-01 02-7010-02 02-7010-03
Pipe Plug, 1" BSP 2 02-7011-01 02-7011-02 02-7011-03
1

Section 8 exploded view & parts listing
Section 8
PX200 ADVANCED METAL Rubber/ TPE-Fitted EXPLODED VIEW
9 10
5
6
7 13 11
27 8 4
12
28
1
3
2
26
14
20
15 21
16
17 22
23
28
27
19
24
30
26
25
29 28
27
PX200 ADVANCED METAL Rubber/ TPE-Fitted PA R T S L I S T I N G
PX200/AAAAA PX200/WWAAA PX200/SSAAA

Item Description Qty. P/N P/N P/N
1 Pro-Flo™ Air Valve Assembly1 1 02-2030-01 02-2030-01 02-2030-01
2 End Cap 2 01-2340-01 01-2340-01 01-2340-01
3 O-Ring (-126), End Cap (1.362 x .103) 2 01-2395-52 01-2395-52 01-2395-52
4 Gasket, Air Valve, Pro-Flo X® 1 02-2620-52 02-2620-52 02-2620-52
5 Gasket, Muffler Plate, Pro-Flo X® 1 02-3502-52 02-3502-52 02-3502-52
6 Muffler Plate, Pro-Flo X® 1 02-3185-01 02-3185-01 02-3185-01
7 Screw, SHC, Air Valve (1/4"-20 x 3") 4 01-6001-03 01-6001-03 01-6001-03
8 Muffler 1 08-3510-99 08-3510-99 08-3510-99
9 Center Section Assembly, Pro-Flo X® 1 02-3146-01 02-3146-01 02-3146-01
10 O-Ring (-206), Air Adjustment Pin (.484 x .139) 1 02-3200-52 02-3200-52 02-3200-52
11 Shaft Seal 2 02-3210-55-225 02-3210-55-225 02-3210-55-225
12 Pilot Sleeve Assembly 1 02-3880-99 02-3880-99 02-3880-99
13 Pilot Spool Retaining O-Ring 2 04-2650-49-700 04-2650-49-700 04-2650-49-700
14 Retaining Ring 2 00-2650-03 00-2650-03 00-2650-03
15 Shaft 1 02-3810-03 02-3810-03 02-3810-03
16 Disc Spring 2 02-6802-08 02-6802-08 02-6802-08
17 Inner Piston 2 02-3701-01 02-3701-01 02-3701-01
18 Diaphragm 2 * * *
19 Outer Piston 2 02-4550-01 02-4550-02 02-4550-03
20 Valve Ball 4 * * *
21 Manifold O-ring 4 * * *
22 Valve Seat 4 02-1125-01 02-1125-08 02-1125-03
23 Valve Seat O-ring 4 * * *
24 Liquid Chamber 2 02-5015-01 02-5015-02 02-5015-03
27 Screw, HHC, 5/16-18 x 1" 32 08-6180-03-42 08-6180-03-42 08-6180-03-42
28 Washer, 5/16 32 02-6731-03 02-6731-03 02-6731-03
29 Pipe Plug, 1" NPT 2 02-7010-01 02-7010-02 02-7010-03
Pipe Plug, 1" BSPT 2 02-7011-03 02-7011-02 02-7011-03
30 Grounding Strap, CSA 1 02-8303-99 02-8303-99 N/A
* Refer to Elastomer Options in Section 9.
1
For submersible Pro-Flo X™ pump, use air valve gasket 02-2621-52 and pipe plug 00-7010-08 or 00-7010-03.
*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 codes or, in the absence of local codes, an industry or nationally recognized code having jurisdiction over the specified installation.

PX200 ADVANCED METAL PTFE-Fitted EXPLODED VIEW
9 10
5
6
7 13 11
8 4
28 12
29
1
3
2
27
14
21
15 22
16
17 23
18
19 24
29
28
20
25
31
27
26
30
29
28
PX200 ADVANCED METAL PTFE-Fitted PA R T S L I S T I N G
PX200/AAAAA PX200/WWAAA PX200/SSAAA

Item Description Qty. P/N P/N P/N
1 Pro-Flo™ Air Valve Assembly1 1 02-2030-01 02-2030-01 02-2030-01
2 End Cap 2 01-2340-01 01-2340-01 01-2340-01
3 O-Ring (-126), End Cap (1.362 x .103) 2 01-2395-52 01-2395-52 01-2395-52
4 Gasket, Air Valve, Pro-Flo X® 1 02-2620-52 02-2620-52 02-2620-52
5 Gasket, Muffler Plate, Pro-Flo X® 1 02-3502-52 02-3502-52 02-3502-52
6 Muffler Plate, Pro-Flo X® 1 02-3185-01 02-3185-01 02-3185-01
7 Screw, SHC, Air Valve (1/4"-20 x 3") 4 01-6001-03 01-6001-03 01-6001-03
8 Muffler 1 08-3510-99 08-3510-99 08-3510-99
9 Center Block Assembly, Pro-Flo X® 1 02-3146-01 02-3146-01 02-3146-01
10 O-Ring (-206), Air Adjustment Pin (.484 x .139) 1 00-1300-52 00-1300-52 00-1300-52
11 Shaft Seal 2 02-3210-55-225 02-3210-55-225 02-3210-55-225
12 Pilot Sleeve Assembly 1 02-3880-99 02-3880-99 02-3880-99
13 Pilot Spool Retaining O-Ring 2 04-2650-49-700 04-2650-49-700 04-2650-49-700
14 Retaining Ring 2 00-2650-03 00-2650-03 00-2650-03
15 Shaft 1 02-3840-03 02-3840-03 02-3840-03
16 Disc Spring 2 02-6802-08 02-6802-08 02-6802-08
17 Inner Piston 2 02-3701-01 02-3701-01 02-3701-01
18 Back-up Diaphragm 2 02-1060-56 02-1060-56 02-1060-56
19 Diaphragm 2 02-1010-55 02-1010-55 02-1010-55
20 Outer Piston 2 02-4601-01 02-4600-02 02-4600-03
21 Valve Ball 4 02-1085-55 02-1085-55 02-1085-55
22 Manifold O-ring 4 70-1280-55 70-1280-55 70-1280-55
23 Valve Seat 4 02-1125-01 02-1125-08 02-1125-03
24 Valve Seat O-ring 4 02-1205-55 02-1205-55 02-1205-55
25 Liquid Chamber 2 02-5015-01 02-5015-02 02-5015-03
28 Screw, HHC, 5/16-18 x 1" 32 08-6180-03-42 08-6180-03-42 08-6180-03-42
29 Washer, 5/16 32 02-6731-03 02-6731-03 02-6731-03
30 Pipe Plug, 1" NPT 2 02-7010-01 02-7010-02 02-7010-03
Pipe Plug, 1" BSPT 2 02-7011-03 02-7011-02 02-7011-03
31 Grounding Strap, CSA 1 02-8303-99 02-8303-99 N/A
1
For submersible Pro-Flo X™ pump, use air valve gasket 02-2621-52 and pipe plug 00-7010-08 or 00-7010-03.
*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 codes or, in the absence of local codes, an industry or nationally recognized code having jurisdiction over the specified
installation.

Section 9
ELASTOMER OPTIONS
P200 & PX200 ADVANCED™ METAL PUMPS
BACK-UP MANIFOLD VALVE SEAT
MATERIAL DIAPHRAGM DIAPHRAGM VALVE BALL O-RING O-RING
Polyurethane 02-1010-50 - 02-1085-50 02-1372-50 02-1205-50
Neoprene 02-1010-51 02-1060-51 02-1085-51 02-1372-51 02-1205-51
Buna 02-1010-52 - 02-1085-52 70-1280-52 02-1205-52
Viton® 02-1010-53 - 02-1085-53 02-1372-53 02-1205-53
EPDM 02-1010-54 02-1060-54 02-1085-54 02-1372-54 02-1205-54
PTFE 02-1010-55 - 02-1085-55 70-1280-55 02-1205-55
Saniflex™ 02-1010-56 02-1060-56 02-1085-56 02-1372-56 02-1205-56
Wil-Flex™ 02-1010-58 - 02-1085-58 02-1372-58 02-1205-58
Neoprene and EPDM back-up diaphragms are available upon request. Please consult your local distributor.
ELASTOMER KIT OPTIONS

NEOPRENE BUNA VITON® EPDM
02-9572-51 02-9572-52 02-9572-53 02-9572-54
PTFE WIL-FLEX™ SANIFLEX™ POLYURETHANE
02-9572-55 02-9572-58 02-9572-56 02-9572-50

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
Note
Notes
Notizen
Anotaciones
Muistiinpanot
Σηµειώσεις
Notater
Notes
Note

Phone +49 2522 77-0 · Fax +49 2522 77-1778

GEA Westfalia Separator Technical Document

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TECHNICAL DOCUMENTATION

EDITION / AUSGABE - 05.11.2010

CUSTOMER / KUNDE: Wärtsilä Finland Oy

PROJECT / PROJEKT: Naryanganj, Bangladesh

WS-Order No. / WS-Bestell No.: 452.911.795

MODEL / MODELL: Lube Oil Treatment

GEA Mechanical Equipment / GEA Westfalia Separator Group GmbH