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
E-Mail: [e-mail] judo.eu
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!