Judo FERROCLEAN User manual

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
E-Mail: [e-mail] judo.eu
Part no.: 1701964
Installation and operating instructions
–Translation –
JUDO FERROCLEAN sludge separator
JFS 2 ½” – 8”
Please transfer to the operator.
Read before installation and commissioning!
Keep for future use.

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
E-Mail: [e-mail] judo.eu
2
Contents
1Introduction.................................................................................................................................................5
1.1 About these installation and operating instructions .............................................................................5
1.2 Validity of these installation and operating instructions .......................................................................5
1.3 Application............................................................................................................................................6
1.3.1 New constructions und restorations..............................................................................................6
1.3.2 System water analysis..................................................................................................................7
1.4 Warranty...............................................................................................................................................7
1.5 Type label.............................................................................................................................................7
2Safety...........................................................................................................................................................8
2.1.1 Intended use.................................................................................................................................8
2.2 Duties of the operator...........................................................................................................................8
2.3 Symbols and their meaning..................................................................................................................9
2.3.1 Hazard notes in the installation and operating instructions ..........................................................9
2.3.2Hazard notes on the sludge separator..........................................................................................9
2.3.3 General notes ...............................................................................................................................9
2.3.4 Personal protective equipment .....................................................................................................9
2.4 General safety instructions.................................................................................................................10
2.4.1 Safety instructions for mechanical working.................................................................................11
2.5 Transport, storage, disposal...............................................................................................................11
3Product information .................................................................................................................................12
3.1 Scope of supply..................................................................................................................................12
3.2 Function description...........................................................................................................................12
3.3 Product overview................................................................................................................................13
3.4 Technical data....................................................................................................................................14
3.4.1 Accessories.................................................................................................................................14
3.4.2 Dimensions .................................................................................................................................15
4Installation.................................................................................................................................................16
4.1 Requirements for the place of installation..........................................................................................16
4.2 Important installation notes................................................................................................................17
4.2.1 Installation example....................................................................................................................18
4.3 Installation..........................................................................................................................................19
5Commissioning.........................................................................................................................................20
5.1 Initial commissioning..........................................................................................................................20
5.2 Flushing interval.................................................................................................................................20
5.3 Flushing process................................................................................................................................21
5.3.1 Flushing process with fresh water ..............................................................................................21
5.3.2 Flushing process with system water...........................................................................................22
5.4 Faults..................................................................................................................................................22
5.5 Removal from service ........................................................................................................................23
6Inspection, maintenance, service...........................................................................................................23
6.1 Replacing the magnesium anode ......................................................................................................24

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
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3
6.2 Replacing the magnetic rods .............................................................................................................24
6.3 Spare parts.........................................................................................................................................24
6.4 Transfer confirmation and maintenance log.......................................................................................25

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
E-Mail: [e-mail] judo.eu
4
Dear customer,
Thank you for the confidence you have shown in us by purchasing this product. In purchasing this JUDO
sludge separator you have procured a state of the art product.
Our aim is that you remain with us as a satisfied customer. Therefore we kindly ask that if you have any
questions concerning your JUDO FERROCLEAN sludge separator or if you have any general questions
concerning water treatment, then please contact our field service representative or directly contact either our
work in Toronto (Canada).
If you have any queries, please specify the model name, order and manufacturing numbers that you can find
on the type label of your JUDO sludge separator.
Every JUDO FERROCLEAN sludge separator has been carefully checked prior to supply. Nevertheless, if
difficulties occur, please contact your responsible customer service representative.
JUDO Water Treatment Inc.
Address:
240 Lesmill Road
Toronto, ON M3B 2T5
Canada
Phone:
[phone]
Toll-free (Canada/USA)
[phone]
Fax:
[phone]
Toll-free fax (Canada/USA)
[phone]
Email:
[email protected]om
judo-online.com

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
E-Mail: [e-mail] judo.eu
5
1 Introduction
1.1 About these installation and operating instructions
These installation and operating instructions should simplify getting to know your JUDO FERROCLEAN
sludge separator and inform you of its intended applications. The installation and operating instructions
contain important information so that you can use the JUDO FERROCLEAN sludge separator safely,
professionally and economically. They contain basic information that must be observed during installation,
operation and maintenance. Observance of this information will help to avoid dangers, reduce repair costs
and increase the reliability and service life of the JUDO FERROCLEAN sludge separator.
Alongside the installation operating instructions and the legal regulations applicable in the country and place
of use in respect of accident prevention, the recognised technical regulations for safe and professional work
must be observed.
All pictorial, dimensional and implementation information correspond to the date of going to press. We
reserve the right to make changes due to technical progress and continuing development. Model and
product claims cannot be lodged.
The installation and operating instructions must always be available at the place of use
of the JUDO FERROCLEAN sludge separator and must be kept in a good, legible state!
All persons involved in installation, commissioning, operation, maintenance, servicing
and repair of the JUDO FERROCLEAN sludge separator must be appropriately qualified
and trained and must have carefully read and understood these installation and
operating instructions and also any separate installation and operating instructions for
other devices and systems!
1.2 Validity of these installation and operating instructions
These installation and operating instructions are valid for the following models:
Designation
Model
Order no.
JUDO FERROCLEAN sludge separator
JFS 2 ½”
8055070
JFS 3”
8055071
JFS 4”
8055072
JFS 5”
8055073
JFS 6”
8055074
JFS 8”
8055075
Tab. 1: Model overview

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
E-Mail: [e-mail] judo.eu
6
1.3 Application
In closed heating and cooling systems, sludge deposits from magnetite (Fe3O4) can lead to faults in
individual system components, massive power losses or even complete system failures. With a JUDO
FERROCLEAN sludge separator system sludge deposits can be deposited and rinsed out and thus, for
example, plate exchangers, tube bundles, air heaters or other system components can be effectively
protected.
High oxygen concentrations are also possible in closed heating and cooling systems. Weak points, e.g. non-
diffusion-tight plastic pipes, allow permanent penetration of oxygen (O2). Surface corrosion occurs in
connection with water, which leads to a continuous material removal. The intensity of the surface corrosion
depends mainly on the oxygen content and time. Silted systems are not only susceptible to faults, but also
work with massively reduced efficiencies. The quality of the system water in silted plants is often unstable
and moves mostly at the limits of the required values at badly blended points. This leads to local,
respectively, selective corrosion (pitting) and the feared breakthroughs. Sludge deposits strongly affect the
heat transfer. Although the performance data of e.g. heat exchangers constantly deteriorate, the negative
effects are often recognized very late.
1.3.1 New constructions und restorations
New constructions:
For larger new systems, it is useful to use a JUDO FERROCLEAN sludge separator from the outset. Thanks
to the simple operation, it is possible to check the system water quality at any time and to determine, with the
help of the magnets and the magnesium anode, whether the system corrodes. Continuous corrosion is
prevented and no sludge can settle.
Restorations:
In the case of refurbishments, a water analysis and accurate inventory of the hydraulic system should be
carried out beforehand. As a result, the correct installation location for the JUDO FERROCLEAN sludge
separator can then be determined. Depending on the system, it may be useful to plan several small models
decentrally. For large systems with floor heating systems, e.g. residential settlements or residential buildings
with central heat generation, JUDO FERROCLEAN sludge separators are installed at the substations, e.g.
decentrally. In the case of cooling systems, the installation location is usually selected in the main mass flow
in the control center.

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
E-Mail: [e-mail] judo.eu
7
1.3.2 System water analysis
To check the system water status in a heating or cooling system, a system water
analysis must be carried out!
It should be noted that the oxygen content can be measured in the system water only
locally, laboratory evaluations are useless and inconclusive!
In order to obtain a statement about the state of the system water, the following values usually have to be
analyzed:
pH Value
Conductivity
Oxygene content
Percentage of dissolved iron / total iron
Possible degree of hardness
1.4 Warranty
The warranty is valid in accordance with our general terms of sale and delivery only if
The JUDO sludge separator is used solely for its intended use and its system components are not
opened, tampered with or incorrectly treated in any other way,
Safety guards are used and these are not manipulated or removed,
The operating conditions correspond to the technical specifications,
Inspection and maintenance are performed according to DIN EN 806-5 2012,
Repairs are only performed with original spare parts by JUDO customer service or authorised
technical personnel.
All work must only be performed by qualified and authorised technical personnel.
1.5 Type label
The type label is located on the front side of the steel tank (see Chap. 3.3)
So that we can more quickly process questions or orders, please specify the type label data.
The optional insulation completely encapsulates the steel container. The insulation must
be removed to be able to read the type plate!

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
E-Mail: [e-mail] judo.eu
8
2 Safety
2.1.1 Intended use
JUDO FERROCLEAN sludge separators are used for the separation and flushing of magnetite sludge
(Fe3O4) and hydrodynamically optimized air separation in closed heating and cooling systems in non-
explosive rooms with a non-condensing and non-aggressive atmosphere within the scope of the possibilities
of use stated in these installation and operating instructions.
Intended use also includes the reading of these installation and operating instructions, adherence to all the
safety conditions and instructions contained within them and the performance of inspection and maintenance
work at the prescribed time intervals.
Attention
Other uses are not compliant with the intended use and not permitted!
JUDO Wasseraufbereitung GmbH will not be responsible for the resulting damage, the
operator alone bears the risk!
2.2 Duties of the operator
The operator of the JUDO sludge separator is responsible for the following:
Only allow qualified and authorised technical personnel to perform inspection, operation,
maintenance, service and repair as well as the training of the operating personnel.
Performance of inspection and instigation of scheduled servicing as part of the regular maintenance
of the corresponding heating and / or cooling system at the prescribed intervals (observe DIN
EN 806-5: 2012).
Constant availability of the installation and operating instructions at the place of use of the JUDO
FERROCLEAN sludge separator.
Perform regular visual inspection of the JUDO FERROCLEAN sludge separator according to the
conditions of use and the hazard potential to prevent leaks and damage.
Storage obligation and transfer of the installation and operating instructions to new owners.
Obligation to insert supplements into the installation and operating instructions.

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
E-Mail: [e-mail] judo.eu
9
2.3 Symbols and their meaning
2.3.1 Hazard notes in the installation and operating instructions
Symbol
Meaning
Symbol
Meaning
Warning
Risk of injuries!
Warning
Danger due to hot surfaces or danger
due to scalding!
Warning
Danger due to magnetic field!
Attention
Risk of malfunctions or damage!
Tab. 2: Hazard notes in the installation and operating instructions
2.3.2 Hazard notes on the sludge separator
Symbol
Meaning
Caution
Hot water - Risk of scalding!
Tab. 3: Hazard notes on the sludge separator
2.3.3 General notes
Symbol
Meaning
Symbol
Meaning
Read and understand the installation
and operating instructions
General information and user tips!
Correct disposal of scrap and operating
resources!
Tab. 4: General notes
2.3.4 Personal protective equipment
Symbol
Meaning
Wear protective gloves!
To protect the hands from damage caused by external effects of a thermal nature.
Tab. 5: Personal protective equipment (PPE)

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
E-Mail: [e-mail] judo.eu
10
2.4 General safety instructions
Warning
Any working methods that might endanger safety must be avoided!
Non-observation of these installation and operating instructions and the safety
instructions herein may endanger persons as well as the environment and the JUDO
FERROCLEAN sludge separator itself.
Warning
Due to the magnetic fields of the high-performance magnets, a sufficient distance to the
JUDO FERROCLEAN sludge separator must be ensured for magnetic data storage
devices as well as electrical and electronic devices!
Persons with heart pacemakers must keep a safety distance of min. 0.5 m from the JUDO
FERROCLEAN sludge separator!
Warning
Danger due to hot surfaces or danger due to scalding!
Wear protective gloves!
The safety instructions do not take into account
Random happenings and events that may occur during installation, operating and maintenance,
Location related safety conditions for the observance of which the operator is responsible, even for
contract installation personnel.
Attention
Unauthorised conversions and changes to the JUDO sludge separator or tampering with
system components are forbidden for safety reasons!
Do not perform any changes, make any additions or carry out any conversions that
could impair safety without the manufacturer’s written approval!
Never remove safety equipment or deactivate it by making changes to the JUDO sludge
separator!
The safety instructions of these installation and operating instructions must be
observed without fail, additional industry-wide and in-house safety instructions remain
in force!
Only operate the JUDO sludge separator with the caps and covers of all system
components correctly closed!
Fault-free operation of the JUDO sludge separator is only ensured if original spare parts
and components are used in the combination described in these installation and
operating instructions, otherwise there is a risk of malfunctioning or damage!
Only allow authorised technical personnel to carry out repairs!
Loose connections must be tightened immediately and damaged system components
immediately replaced!

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
E-Mail: [e-mail] judo.eu
11
2.4.1 Safety instructions for mechanical working
Warning
Before cleaning, maintenance or repair work ensure that the JUDO FERROCLEAN
sludge separator is hydraulically depressurised!
These activities must only be performed by JUDO customer service or authorised
technical personnel, who know and understand the overall system of the JUDO sludge
separator and its environment!
2.5 Transport, storage, disposal
Attention
Transport the JUDO sludge separator with care in an upright position, do not knock
over, do not transport when there is a risk of frost, also protect against dust and dirt
effects!
Attention
Dry, frost-proof storage location with aggressive atmosphere!
Protect the JUDO UV sludge separator against coarse dust and dirt as well as UV
radiation and direct sunshine!
Recommended storage temperature: +4 °C to +40 °C!
Scrap and operating resources must be disposed of in accordance with the valid
regulations or routed for reuse and recycling (for scrap and operating resources that are
subject to particular conditions, observe the corresponding instructions on the
packaging or obtain the necessary information from the responsible disposal facilities,
specialist companies or from the manufacturer/supplier)!

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
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3 Product information
3.1 Scope of supply
JUDO FERROCLEAN sludge separator comprising
Steel container welded with flange connection and support legs
1 set of high performance magnetic rods (4 pieces)
Magnesium anode
Ventilator with shut-off cock
Shut-off cock input flush water as well as output blow down
Installation and operating instructions
Using your order, check the supplied parts for completeness and sound condition!
The product is supplied fully assembled!
Damage caused by transport must be reported inside 24 hours, otherwise no damage
claims can be settled for insurance reasons!
3.2 Function description
The high-performance magnets of the JUDO FERROCLEAN sludge separator bind the magnetic sludge
(magnetite) in the medium, at the same time the oxygen is decomposed via the magnesium anode. The gas
bubbles carried by the flow trap and collect in an internal separation device, from there they rise in a calm
zone and are removed from the circulation system via the automatic breather.
The JUDO FERROCLEAN sludge separator operates at a constant flow rate. The entire amount of water is
filtered continuously, the magnetite sludge circulating in the system for a long time is being completely
covered by the high-performance magnets.
In a second chamber, the water is passed through a magnesium field which settles the existing oxygen
concentration.
Depending on the degree of sludge in the system, the deposited magnetite sludge must be rinsed from the
JUDO FERROCLEAN sludge separator at regular intervals.

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
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3.3 Product overview
Fig. 1: Overview Fig. 2: With insulation
1
Base plate of the support legs
8
Bleeding device
2
Sludge
9
Bleeding shut-off valve
3
Sludge shut-off ball valve
10
Steel container welded
4
Type label
11
Flange connection
5
Flange connection
12
High-performance magnetic rods, 4x
6
Magnesium anode
13
Support legs
7
Flushing water shut-off valve
14
Insulation (optional accessory)
2
3
4
5
6
7
9
8
10
12
11
13
14
1

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
E-Mail: [e-mail] judo.eu
14
3.4 Technical data
Performance data
JFS
2 ½”
3”
4”
5”
6”
8”
Rated flow
[m³/h]
12
17
30
50
80
130
Mechanical, hydraulic data
Nominal diameter
2 ½”
3”
4”
5”
6”
8”
Flush water connection
(inlet)
["]
½ IG
Sludge connection (to sewer)
["]
1 IG
Max. permissible operating
pressure
[bar]
16
Ventilation effect up to
max.
[bar]
10
Pressure drop (at rated flow)
[bar]
< 0,01
Permissible temperature of
medium
[°C]
6 - 130
Weight
FERROCLEAN sludge
separator
[kg]
48
52
58
64
70
76
Tab. 6: Technical data
3.4.1 Accessories
Designation
Order no.
JUDO insulation for model JFS 2 ½”
8057501
JUDO insulation for model JFS 3”
8057502
JUDO insulation for model JFS 4”
8057503
JUDO insulation for model JFS 5”
8057504
JUDO insulation for model JFS 6”
8057505
JUDO insulation for model JFS 8”
8057506
Tab. 7: Accessories
Accessories are not supplied!

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
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15
3.4.2 Dimensions
Fig. 3: Dimensions
Model
A
B
C
D
E
F
G
H
I
J
K *
JFS 2 ½”
575
435
349
655
295
416
1026
1143
500
273
373
JFS 3”
575
435
349
655
295
416
1026
1143
500
273
373
JFS 4”
575
435
349
655
295
416
1026
1143
500
273
373
JFS 5”
575
435
349
655
295
416
1026
1143
500
273
373
JFS 6”
575
435
349
655
295
416
1026
1143
500
273
373
JFS 8”
575
435
349
655
295
416
1026
1143
500
273
373
Tab. 8: Dimensions
*
With JUDO insulation (optional accessory)

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
E-Mail: [e-mail] judo.eu
16
4 Installation
Attention
A sufficiently sized floor drain (in accordance with DIN EN 12056) must be installed at
the place of use for the eventuality that leaking of the JUDO FERROCLEAN sludge
separator or its feed pipe could result in extensive damage!
Assure yourself that prior to connection of the pipes no impurities can enter the JUDO
FERROCLEAN sludge separator from the pipe system (e.g. residues from installation
work)!
Accordingly cleaning of the entire new installation may be necessary!
4.1 Requirements for the place of installation
An on-site bypass (bypass) with on-site shut-off valve is provided in order to avoid
interruptions in operation of the system during maintenance and repair work on the
JUDO FERROCLEAN sludge separator (see mounting example in the bypass Chap. 4.3,
Fig. 6)!
The JUDO sludge separator must be installed in a dry, frost-proof location with a condensation-free
and non-aggressive atmosphere.
Ensure there is enough space available for installation, maintenance and repair work and also for
ready accessibility.
An adequately sized sewer connection in compliance with DIN EN 12056 must be fitted to drain
away any permeate without backing up occurring.
The permeate line must be fixed to the permeate connection to prevent scalding by hot water. It
must be in the same dimension as the permeate connection and must be laid steadily downwards to
the sewer, with a free outlet above the sewer connection.
If a retention pond (pump sump) is installed for the waste water, it must be ensured that the pump
used there can drain the waste water off and/or that an alarm is triggered upon “overfull” of the
retention pond.

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
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17
4.2 Important installation notes
Attention
Loads occurring, e.g. due to temperature fluctuations, may have to be compensated for
by fitting of suitable on-site compensators!
Alternating loads, e.g. pressure surges, abrupt pressure changes and strong vibrations
have to be avoided!
We recommend the use of a JUDO insulation (see Chap. 3.3 and 3.4.1) to prevent the
formation of condensed water!
Install the JUDO sludge separator on a level surface in a stable manner.
The JUDO FERROCLEAN sludge separator can be installed in the flow or return of the system, the
flow direction is freely selectable.
The JUDO FERROCLEAN sludge separator can be integrated into the installation using
commercially available valves and fittings. The pipelines on the customer's site must be
mechanically stress-free and the connections must be mechanically stress-free and sealed.
Shut-off valves must be installed on-site at the inlet and outlet side.
In order to flush the JUDO FERROCLEAN sludge separator with fresh water, it must be
mechanically stress-free sealed connected to the connection of the flushing water by means of a
safety device provided by the customer. Alternatively, the JUDO FERROCLEAN sludge separator
can be flushed with system water.
For simple operation and maintenance ensure the specified space requirement is available.
The system-specific operating data must be complied with.
If the JUDO FERROCLEAN sludge separator is connected to the public water mains, installation
upstream of the water meter is only permitted with the permission of the water company.
Adhere to DIN EN 806, DIN EN 12056, DIN 1988-200, DIN EN 1591-4 and DIN EN 1092-2.
Observe the separate installation and operating instructions of other devices and systems.
Observe technical information, local installation regulations and general guidelines (e.g. EVU, VDE,
WVU, DIN, DVGW, ÖVGW, SVGW).
Problem solutions and other installation options can be clarified by a JUDO technical consultation.

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
E-Mail: [e-mail] judo.eu
18
4.2.1 Installation example
Fig. 4: Installation example in the system return flow

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
E-Mail: [e-mail] judo.eu
19
4.3 Installation
Attention
Perform installation acc. to DIN-EN 1591-4
The JUDO FERROCLEAN sludge separator can be installed in the flow or return of the
system, the flow direction is freely selectable!
Mounting means are not included in the scope of supply!
Fig. 5: Installation
1
Hexagon screw*
5
Flange connection JUDO FERROCLEAN
2
Washer*
6
Washer*
3
On-site flange connection
7
Nut*
4
Sealing of the fabric insert
* Amount depending on model and amount of screw
holes
Fig. 6: Example of installation with bypass
1
2
3
4
6
7
7
6
4
3
2
1
5
5
1 Inflow or return flow of the system
(flow direction is fully selectable)
2 Shut-off valve in the bypass
3 Shut-off valve:
4 Shut-off valve:
1
2
3
4

Installation and operating instructions: JUDO FERROCLEAN sludge separator JFS 2 ½” – 8”
All rights reserved.
JUDO Wasseraufbereitung GmbH
© JUDO Wasseraufbereitung GmbH
Postfach 380 D-71351 Winnenden
Translation into foreign languages and reproduction, even in excerpt form, is only permitted with special
approval.
Tel. [phone] Fax [phone]
Revision level: 20.04.2017
E-Mail: [e-mail] judo.eu
20
5 Commissioning
Attention
Prerequisite for commissioning is the correct installation of the JUDO FERROCLEAN
sludge separator!
The commissioning must only be performed by JUDO customer service or authorised
technical personnel!
The transfer confirmation (see Chap. 6.4) must be carefully filled out upon
commissioning!
5.1 Initial commissioning
During initial commissioning, it must be ensured that
- no visible damage to the JUDO FERROCLEAN sludge separator as well as its system components
is present,
- the JUDO FERROCLEAN sludge separator is properly integrated in the installation,
- all connections are checked for leak-tightness,
- the drainage system is ready,
- all magnetic rods are properly inserted in the JUDO FERROCLEAN sludge separator,
- the on-site shut-off valve is closed in the bypass,
- the onsite shut-off valves on the inlet side and outlet side (1+2) of the JUDO FERROCLEAN sludge
separator are opened,
- the bleed valve (5) and shut-off cock of the ventilation (4) is opened,
- the shut-off cock of the flushing water (3) and the sludge shut-off valve (7).
5.2 Flushing interval
Depending on the degree of sludge in the system, the deposited magnetite sludge must
be rinsed from the JUDO FERROCLEAN sludge separator at regular intervals.
For heavy sludging, a monthly rinse interval is recommended, in extreme cases, an even
shorter rinse interval may be required at the beginning!
Normal sludge can be reduced to a half-year rinsing interval!