8090 9001 100

Westfalia Separator AG
Mechanical Separation
Division
Instruction Manual
No.: 8090-9001-100
Edition: 0306
Designation: Centrifugal mixer
for explosion-hazarded zones
Type: ZA 40, ZA 80, ZA 100
2 Westfalia Separator AG
©
All rights reserved. No part of this document may be reproduced in any form – by graphic, electronic or me-
chanical means including all types of photocopying or any other means of duplication – without our prior written
consent.
The transmission of originals and reproductions to third parties is prohibited without our prior consent.
8090-9001-100 / 0306
Westfalia Separator AG 3
1 Introduction 7
1.1 About this manual .................................................................................... 8

1.2 For your safety......................................................................................... 9
1.3 Note on the symbols used in the documentation .................................. 10
2 Safety precautions 13
2.1 Fundamental safety precautions ........................................................... 15

2.1.1 Other elements on the machine ............................................................ 15
2.2 Symbols and abbreviations used........................................................... 15
2.2.1 Concrete safety precautions and symbols used.................................... 15
2.2.2 Further symbols for information............................................................. 16
2.3 Correct usage ........................................................................................ 16
2.3.1 Incorrect usage ...................................................................................... 17
2.4 Safety markings on the machine ........................................................... 19
2.4.1 Current safety markings as from 2004 .................................................. 19
2.4.2 Meaning of the safety markings............................................................. 20
2.4.3 Obligations of the user........................................................................... 24
2.4.4 Qualification of the personnel ................................................................ 25
2.4.5 Notes on the use of protective equipment ............................................. 27
2.4.6 Unauthorized modification work ............................................................ 28
2.4.7 Use of non-genuine spare parts ............................................................ 28
2.4.8 Safety precautions for the electrical installation .................................... 29
2.4.9 Position of safety devices on the centrifugal mixer ............................... 29
2.4.10 The main switch on the control cabinet ................................................. 29
2.4.11 EMERGENCY-OFF switches ................................................................ 29
2.4.12 Checking safety devices, e.g. Emergency-Off....................................... 29
2.5 Special safety precautions..................................................................... 30
2.5.1 Safety precautions for transport ............................................................ 30
2.5.2 Special risks of a centrifugal mixer ........................................................ 31
2.5.3 Special product hazards ........................................................................ 32
2.5.4 Safety precautions for operating the centrifugal mixer with hazardous
materials ................................................................................................ 33
2.5.5 Special hazards caused by cleaning liquid............................................ 34
2.5.6 Steam sterilization ................................................................................. 35
2.5.1 Hazard due to explosive materials (Ex-zone)........................................ 36
2.6 Additional notes ..................................................................................... 38
2.6.1 Operating principles............................................................................... 38
2.6.2 Bowl speed and product ........................................................................ 38
2.7 Working on the machine / regular checks ............................................. 38
2.7.1 Assembly ............................................................................................... 39
2.7.2 Before start-up ....................................................................................... 40
2.7.3 Safety precautions for start-up .............................................................. 41
2.7.4 Start-up .................................................................................................. 42
2.7.5 Safety precautions for operation............................................................ 42
2.7.6 Safety precautions for maintenance and repair..................................... 43
2.7.7 Corrosion ............................................................................................... 46
2.7.8 Erosion................................................................................................... 47
2.8 Sight glasses ......................................................................................... 48
2.9 Prior to a long-term shut-down .............................................................. 49
2.9.1 Final decommissioning .......................................................................... 50
2.9.2 Disposing of the machine ...................................................................... 51
2.9.3 Disposal of cleaning liquids ................................................................... 51
8090-9001-100 / 0306
3 Machines in explosion-hazarded zones 53
3.1 Instructions for the operator................................................................... 54

3.1.1 Machines in explosion-hazarded zones ................................................ 55
3.2 Machine protection concepts ................................................................. 56
3.2.1 Inerting machine chambers ................................................................... 57
3.2.2 Measures when using inerting systems................................................. 57
3.3 Requirements to be met by the inert gas system .................................. 59
3.3.1 Classifying the machines ....................................................................... 59
3.3.2 Applicable standards, regulations.......................................................... 59
3.3.3 Overview schematic centrifugal mixer ................................................... 60
3.3.4 Operating modes “purging and operation”............................................. 60
3.3.5 Inerting the centrifugal mixer ................................................................. 62
3.3.6 Calculating the purging time .................................................................. 63
3.3.7 Flow measurement ................................................................................ 64
3.3.8 Monitoring drive components ................................................................ 64
3.4 Installation and adjustment .................................................................... 65
3.4.1 Electrical installation .............................................................................. 65
3.4.2 Rating the inert gas line ......................................................................... 65
3.5 Commissioning ...................................................................................... 67
3.5.1 Start-up and operation ........................................................................... 67
3.5.2 Start-up with automatic purging............................................................. 67
3.5.3 Note on start-up after an interruption in production............................... 67
3.5.4 Operation monitoring ............................................................................. 67
3.5.5 Shut-down.............................................................................................. 67
3.5.6 Opening the machine............................................................................. 68
3.6 Maintenance .......................................................................................... 68
3.7 Spare parts ............................................................................................ 68
4 Machine description 69
4.1 Application ............................................................................................. 70

4.2 Construction........................................................................................... 70
4.3 Method of operation............................................................................... 70
4.4 Hermetic design..................................................................................... 70
4.5 Feed and discharge ............................................................................... 70
4.6 Materials ................................................................................................ 71
5 Installation 73
5.1 Installing the mixer in ATEX zone 1....................................................... 75
6 Motor connection 77
6.1 Three-phase AC motor .......................................................................... 78

6.2 Explosion-proof three-phase AC motor ................................................. 79
6.3 Speed of the bowl ................................................................................. 80
6.4 Starting time of the bowl ........................................................................ 80
6.5 Direction of rotation of bowl ................................................................... 80
7 Lubrication 81
8090-9001-100 / 0306
7.1 Bowl parts .............................................................................................. 82

7.2 Motor bearings....................................................................................... 82
7.3 Sealing rings of the housing .................................................................. 82
8 Bowl 83
8.1 Important hints ....................................................................................... 84

8.2 Dismantling ( ZA 40 ) ............................................................................. 86
8.3 Assembly ( ZA 40 ) ................................................................................ 88
8.4 Dismantling (ZA 80/100) ........................................................................ 93
8.5 Assembly (ZA 80/100) ........................................................................... 95
9 Operation 99
9.1 Before every start-up ...........................................................................100

9.2 Start-up ZA ..-66- .................................................................................101
9.3 Start-up ZA ..-67- .................................................................................101
9.3.1 Shut-down............................................................................................102
9.3.2 Opening the machine...........................................................................103
9.4 Maintenance ........................................................................................103
9.4.1 Maintaining the motor bearings ...........................................................103
10 Datasheet 105
10.1 Data sheet ...........................................................................................107
8090-9001-100 / 0306
8090-9001-100 / 0306
1 Introduction
1.1 About this manual .................................................................................... 8

1.2 For your safety......................................................................................... 9
1.3 Note on the symbols used in the documentation .................................. 10
8090-9001-100 / 0306
1.1 About this manual
This manual is part of the documentation supplied with the centrifugal mixer.
Everyone who works with or on this centrifugal mixer must have read and un-
derstood this manual and the safety precautions contained in it.
In the interest of your personal safety and a better understanding of the

machine, please first read the safety precautions and then the following
chapters.
NOTE
This booklet must be kept for further use and be available at all times in
the vicinity of the centrifugal mixer for all persons who work with or on
the centrifugal mixer.
HINWEIS
The documentation contains important information for all persons who

work with or on the centrifugal mixer. Non-compliance with the instruc-
tions in the documentation can not only result in danger for machines,
Caution material and environment but also endanger persons who work on or in
the environment of the centrifugal mixer.
(danger to life, risk of injury)
At the beginning of this manual, you will find the schematic of the cen-
trifugal mixer and the nameplate. The nameplate must be filled in by the
operator. Enter the data from the nameplate on the centrifugal mixer.
NOTE Dangers of later confusion are thus avoided.
8090-9001-100 / 0306
1.2 For your safety
• Observe accident prevention regulations.
The local safety and accident prevention regulations apply uncondi-

tionally to the operation of the centrifugal mixer.
• Refer to the documentation supplied.
Proceed only in accordance with the documentation supplied.
• Operate the centrifugal mixer only in accordance with agreed

process and operating parameters.
• Maintain the centrifugal mixer.
as specified in the documentation supplied.
• Carry out safety checks on the centrifugal mixer,
as described in the documentation supplied.
• 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 personnel or if the machine is not ap-
plied in accordance with the intended use.
Westfalia Separator AG shall not be liable for damage which occurs
as a result of non-compliance with the above. Warranty and liability
conditions in the Conditions of Sale and Delivery of Westfalia Sepa-
rator AG are not extended by the above.
8090-9001-100 / 0306
1.3 Note on the symbols used in the documentation
Below is an explanation of the meaning of the symbols used in the documenta-

tion.
Special attention must be paid to all passages in the documentation marked
with safety symbols. The operation described after such a symbol must be car-
ried out with utmost care.
This symbol indicates potential danger to persons.

Caution
This symbol indicates potential risk to risks for machine, material and
environment.
Attention!
This symbol draws attention to the fact that at this point additional manu-
als must be read and observed.
Instruction manual
This symbol does not indicate safety precautions but rather information
for a better understanding of the machine.
NOTE
8090-9001-100 / 0306
Fig. 1
Westfalia Separator
…………….GmbH
D-59302 Oelde ( Germany)
Type Serial-No.
Model
Max. admissible rated bowl speed in min-1
Max. admissible density in kg/dm3 of product
Heavy liquid kg/dm3 Solids kg/dm3
min/max throughput m3/h
min./max. temperature of product in °C
min/max housing pressure range in bar
8090-9001-100 / 0306
Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
8090-9001-100 / 0306
2 Safety precautions
2.1 Fundamental safety precautions ........................................................... 15

2.1.1 Other elements on the machine ............................................................ 15
2.2 Symbols and abbreviations used........................................................... 15
2.2.1 Concrete safety precautions and symbols used.................................... 15
2.2.2 Further symbols for information............................................................. 16
2.3 Correct usage ........................................................................................ 16
2.3.1 Incorrect usage ...................................................................................... 17
2.4 Safety markings on the machine ........................................................... 19
2.4.1 Current safety markings as from 2004 .................................................. 19
2.4.2 Meaning of the safety markings............................................................. 20
2.4.3 Obligations of the user........................................................................... 24
2.4.4 Qualification of the personnel ................................................................ 25
2.4.5 Notes on the use of protective equipment ............................................. 27
2.4.6 Unauthorized modification work ............................................................ 28
2.4.7 Use of non-genuine spare parts ............................................................ 28
2.4.8 Safety precautions for the electrical installation .................................... 29
2.4.9 Position of safety devices on the centrifugal mixer ............................... 29
2.4.10 The main switch on the control cabinet ................................................. 29
2.4.11 EMERGENCY-OFF switches ................................................................ 29
2.4.12 Checking safety devices, e.g. Emergency-Off....................................... 29
2.5 Special safety precautions..................................................................... 30
2.5.1 Safety precautions for transport ............................................................ 30
2.5.2 Special risks of a centrifugal mixer ........................................................ 31
2.5.3 Special product hazards ........................................................................ 32
2.5.4 Safety precautions for operating the centrifugal mixer with hazardous
materials ................................................................................................ 33
2.5.5 Special hazards caused by cleaning liquid............................................ 34
2.5.6 Steam sterilization ................................................................................. 35
2.5.1 Hazard due to explosive materials (Ex-zone)........................................ 36
2.6 Additional notes ..................................................................................... 38
2.6.1 Operating principles............................................................................... 38
2.6.2 Bowl speed and product ........................................................................ 38
2.7 Working on the machine / regular checks ............................................. 38
2.7.1 Assembly ............................................................................................... 39
2.7.2 Before start-up ....................................................................................... 40
8090-9001-100 / 0306
2.7.3 Safety precautions for start-up .............................................................. 41

2.7.4 Start-up .................................................................................................. 42
2.7.5 Safety precautions for operation............................................................ 42
2.7.6 Safety precautions for maintenance and repair..................................... 43
2.7.7 Corrosion ............................................................................................... 46
2.7.8 Erosion................................................................................................... 47
2.8 Sight glasses ......................................................................................... 48
2.9 Prior to a long-term shut-down .............................................................. 49
2.9.1 Final decommissioning .......................................................................... 50
2.9.2 Disposing of the machine ...................................................................... 51
2.9.3 Disposal of cleaning liquids ................................................................... 51
8090-9001-100 / 0306
2.1 Fundamental safety precautions

These general safety precautions form part of the overall documentation pack-
age furnished with the centrifugal mixer. They contain information which is im-
portant for safe handling of centrifugal mixers.
Every person assigned the responsibility of installing, operating, maintaining and

repairing the centrifugal mixer must have read and understood the documenta-
tion, in particular the chapter safety precautions.
Maintenance and repair work may only be carried out by the user to the extent
described in this instruction manual. The user must ensure that all work is car-
ried out by suitably qualified personnel (see also “Qualification of the person-
nel”).
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.
The instruction manual and further documentation required for the operation of
the centrifugal mixer / plant must be complete and kept in the vicinity of the cen-
trifugal mixer for ready access by the operating personnel. It must be available
to the operators at all times. Damaged and/or illegible parts must be replaced.
2.1.1 Other elements on the machine

All measuring, control and / or safety elements on the machine as well as
valves, pumps and other auxiliaries not manufactured by Westfalia Separator
are not described in the machine documentation.
To avoid operating errors and safety risks, the instructions and equipment
descriptions of the respective manufacturers must be observed. They
contain instructions on assembly, commissioning, safe operation and
Instruction manual maintenance.
The positions of special safety devices such as sensors must not be changed.
Safety devices must not be put out of operation.
2.2 Symbols and abbreviations used

In the following instruction manual, concrete safety precautions are given to
draw attention to the non-avoidable residual risks when operating the machine.
The symbols and warning signs used in the instruction manual correspond to
the symbols used in standard sets of regulations. They are described in detail in
the chapter Safety precautions and are intended to draw attention to potential
danger sources to minimise the risk of accidents for persons and / or damage to
property.
2.2.1 Concrete safety precautions and symbols used

These residual risks involve hazards for
• persons
8090-9001-100 / 0306
• product and machine

• environment.
The symbols used in the instruction manual are above all designed to draw at-
tention to the safety precautions.
This symbol indicates potential danger to persons.

Caution
This symbol indicates potential risks to machine, material and environ-

ment.
Attention!
The most important aim of the safety precautions is to prevent personal injury.
The respective symbol used cannot replace the text of the safety precaution.
Therefore, always read the complete text!
2.2.2 Further symbols for information

The following symbols are not safety precautions but represent information and
notes to enable better understanding of the machine or plant and processes.
This symbol draws attention to the fact that at this point additional manu-
als must be read and observed.
Instruction manual
• If the stop sign with the caption “Instruction manual” is in front of a note, an-
other furnished manual must be referred to and the instructions and notes ob-
served.
This symbol does not indicate safety precautions but rather information
for a better understanding of the machine.
NOTE
• When the info symbol with the caption “Note” is adjacent to a text, the reader
is given useful tips, explanations and notes on the machine, plant or its proc-
esses.
2.3 Correct usage
The centrifugal mixer is used for mixing liquids. It satisfies the requirements for
the application of a centrifugal mixer in explosion-hazarded zones in accordance
with ATEX II 2 G X.
8090-9001-100 / 0306
The centrifugal mixer is designed

• in accordance with the chemical and physical properties of the product speci-
fied for correct usage of the centrifugal mixer and
• in accordance with the method of application contractually agreed with West-
falia Separator AG.
The centrifugal mixer may be operated only in the agreed areas and with the pa-
rameters specified in the documentation or a data sheet which is part of the
documentation.
Any operating mode deviating herefrom is not proper and correct and can
cause damage to persons and property.
NOTE
In particular, only products may be used which conform to the specifications on

the centrifugal mixer nameplate.
The instructions, notes and specifications in the instruction manual must be fol-
lowed.
2.3.1 Incorrect usage

All operating modes not detailed under correct usage are considered to be in-
correct usage.
• Products not specified in the documentation or on a datasheet furnished with

the documentation may not be used.
• Constructional alterations may not be made to the centrifugal mixer, fittings

and other accessories.
• Use only those operating materials specified in the technical data or technical
specifications (lubricating greases, cleaning agents, operating liquids etc.)!
• Process parameters such as
– admissible pressures
– admissible temperatures
– admissible flow rates
– torques
– settings
which are specified in the user information or a datasheet furnished with the
user information must not be exceeded.
Prior to any intended deviation from the agreed operating mode, it is imperative
to obtain the consent of Westfalia Separator.
8090-9001-100 / 0306
Westfalia Separator shall not accept liability for damage arising from in-
correct usage.
NOTE
8090-9001-100 / 0306
2.4 Safety markings on the machine
The safety markings on the machine are intended to indicate risks which may
occur during operation of the machine. To protect the operators, we have re-
vised the safety markings for centrifuges in cooperation with the German Em-
ployer’s Liability Insurance Association to further improve the world-wide com-
prehensibility. After a transition period, only the new safety markings will be
used on the machines.
Since the safety precautions under discussion apply for all machines from West-
falia Separator, there may be both old and new safety markings on the ma-
chines. For this reason, the old and new safety markings are introduced and
explained below.
The safety markings attached to the machine must always be in perfect condi-
tion. They are part of the user information.
• Clean dirty safety markings.
• Replace damaged safety markings.
2.4.1 Current safety markings as from 2004
Fig. 2
8090-9001-100 / 0306
Fig. 3
Fig. 4
2.4.2 Meaning of the safety markings
It is very important that everyone who works with or on the machine is

familiar with the meaning of all symbols on the safety stickers. The stick-
ers are attached either to the machine or the control cabinet belonging to
NOTE the machine.
8090-9001-100 / 0306
• Machine documentation:
• Read it before working on the
machine.
Fig. 5
These safety markings mean:

Read machine documentation.
The operator must ensure that only persons work on the machine who are
able to read and understand the machine documentation.
In case of non-observance of the above, Westfalia Separator accepts no
liability for resulting damage.
Before working on the machine:

• Ensure that the machine is at a
standstill.
• Switch off the main switch.
• Lock the main switch to prevent
re-starting.
Fig. 6
This safety marking means:

Before working on the machine and electrical plant components:
Ensure that the machine is at a standstill. Disconnect power to the ma-
chine and plant components and secure against unintentional switching
on!
Danger of injury through electrical current and unintentional start-up of
the machine!
8090-9001-100 / 0306
• Frequency converter operation

• The admissible maximum bowl
speed must not be exceeded.
Fig. 7

Attention, do not manipulate the frequency converter (electronic speed adjust-
ment)! Setting the parameters on the frequency converter may only be
carried out by qualified specialists. The admissible maximum bowl speed
as stated on the nameplate must not be exceeded! When starting the ma-
chine, for example after replacing drive parts, the bowl speed must be
checked.
The machine may only be operated with an additional independent device
for speed limiting.
Risk of damage to the machine!
8090-9001-100 / 0306
• Extreme surface temperatures
Fig. 8
These safety markings mean:

Attention, the surfaces of the machine and plant components can be hot
or cold.
Danger of injury through hot or cold surfaces!
8090-9001-100 / 0306
2.4.3 Obligations of the user

The centrifugal mixer corresponds to the state-of-the-art of the year of its con-
struction and makes possible a high level of safety when operated for its correct
intended use.
In practical operation, however, the high safety standard can only be maintained
through compliance with all required measures. The user of the centrifugal
mixer must therefore practice the required care and diligence in planning these
measures and monitoring their execution.
The user must in particular comply with national legislation and directives.
The user must, for example, ensure that

• the centrifugal mixer is applied only for the intended use (see section Correct
usage).
• the centrifugal mixer is operated only in a perfect functional condition and the
function of the safety devices is regularly checked.
• necessary personal protective gear is available and worn by operating, main-

tenance and repair personnel.
• the instruction manual is always available at the centrifugal mixer site in a

complete and legible condition.
• only qualified and authorized personnel operate, maintain and repair the
separator.
• this personnel receives regular instruction on all relevant issues relating to in-
dustrial safety and environmental protection and is familiar with the instruction
manual and, in particular, the safety precautions contained in it.
• all safety and warning signs are not removed and remain legible.
• a plant instruction on conduct at the workplace is issued by the user and

made known to the personnel.
• in Germany the local accident prevention regulations of the employer’s liability

insurance association are complied with.
• safe access to the machine is assured for maintenance and repair work, for
example by means of catwalks and working platforms.
• the corresponding statutory safety regulations for the protection of life and
health are adhered to.
8090-9001-100 / 0306
Assembly and commissioning personnel of Westfalia Separator have

been directed to abort operations when statutory safety regulations at the
site of deployment are not fulfilled and there is a risk to life and health.
NOTE
• The user must ensure that the required hoists, devices and aids are available
to ensure safe handling of the centrifugal mixer during assembly work.
2.4.4 Qualification of the personnel
The centrifugal mixer may only be operated, maintained and repaired by trained
personnel.
The user of the centrifugal mixer is responsible for training.
The personnel must likewise receive instruction in the required accident preven-
tion measures and know and understand the plant instructions.
The user must deploy personnel who are capable of

– fulfilling the requirements to be met by the personnel for operating the cen-
trifugal mixer.
– reading the markings on the centrifugal mixer and the instruction manual.
The personnel must be trained to carry out the following operations on tzhe cen-
trifugal mixer:
• Operation
• Maintenance
• Repair
The user is acting with gross negligence when he deploys untrained, unsuitable
personnel for work on the centrifugal mixer and knowingly exposes the person-
nel to a life-threatening risk.
Operation of the centrifugal mixer or plant by untrained or unauthorized person-

nel can result in
– danger to life and limb of the user or third parties.
– impairment of or damage to the centrifugal mixer or plant or other assets of
the user.
– reduction of the efficiency of thee centrifugal mixer or plant.
Westfalia Separator shall accept no liability for damage caused by un-

qualified or unauthorized personnel.
8090-9001-100 / 0306
Westfalia Separator offers a comprehensive range of training measures. Con-

tact Westfalia Separator or one of its authorized representatives for further in-
formation.
8090-9001-100 / 0306
2.4.5 Notes on the use of protective equipment

To avoid danger to life and limb, the specified protective gear must be worn by
operating, maintenance and repair personnel in line with the
– local accident regulations,

– plant instructions issued by the operator or employer and
– the safety precautions described in this instruction manual.
Examples of personal protective gear:

The following protective gear must be worn when in the vicinity of or working on
the separator
Wear ear protection when working in loud environments!

[The noise level in a plant can exceed 85dB(A)]
Wear ear protection!
Wear protective gloves when working on hot or cold surfaces of separator

and piping.
(possible temperature ranges <-10 bis >80°C or <14 bis >176 °F)
When working with hazardous products, on bowl disks as well as on sur-

faces of machine components which may have sharp edges.
Wear protective gloves!
Wear protective goggles when working on pipes and fittings.

(Possible residues of caustic liquids in valves and pipes and piping sys-
tem not relieved from pressure)
Wear protective goggles!
8090-9001-100 / 0306
2.4.6 Unauthorized modification work

No conversion work or modifications may be carried on the centrifugal mixer or
plant by the user.
Conversions or modifications to the centrifugal mixer or plant can

– endanger life and limb of the user or third parties.
– impair the operating safety of the centrifugal mixer.
– lessen the efficiency of the centrifugal mixer / plant.
– result in damage to the centrifugal mixer itself or other components within
the plant.
Westfalia Separator shall not assume liability for damage arising from
unauthorized conversion or modification to the centrifugal mixer or plant.
NOTE
2.4.7 Use of non-genuine spare parts
Safety risks can arise from the use of non-genuine spare parts. In addition, the
durability of such parts is frequently significantly lower which leads to a higher
maintenance requirement and lower plant availability.
If a safety risk arises, this may have legal consequences for the responsible
persons. In this case, Westfalia Separator shall assume no liability or warranty.
• Damaged separator parts must be replaced by new genuine spare parts from
Westfalia Separator.
8090-9001-100 / 0306
2.4.8 Safety precautions for the electrical installation
• The local regulations apply for the

electrical appliances and installa-
tions.
• The frequency and voltage of the
power supply must correspond to
the machine specifications.
• Carry out voltage equalization.
• Observe statutory regulations; e.g.
in the EU the EG guidelines:
2.4.9 Position of safety devices on the centrifugal mixer

Special safety devices such as sensors are customer-specific and must not be
changed.
2.4.10 The main switch on the control cabinet

Precise information on the position of the main switch on the control cabinet is
given in the electrical documentation.
The control cabinet is installed in accordance with the installations of the user.
The position of the main switch must therefore be taken from the plant instruc-
tion of the user.
2.4.11 EMERGENCY-OFF switches

EMERGENCY-OFF switches are located in the control cabinet.
Precise information on the position of the EMERGENCY-OFF switches is given
in the electrical documentation.
The control cabinet is installed in accordance with the installations of the user.
The position of the EMERGENCY-OFF switches must therefore be taken from
the plant instructions of the user.
2.4.12 Checking safety devices, e.g. Emergency-Off

The safety devices must be correctly installed and checked for functionality be-
fore start-up.
Further information on this, taking into account the plant-specific conditions, can
be found in the plant procedure defining conduct at the workplace. The plant
procedure must be issued by the user and is not identical to the instruction
manual published by Westfalia Separator.
8090-9001-100 / 0306
2.5 Special safety precautions

The following safety precautions apply for centrifugal mixers and plant compo-
nents delivered by Westfalia Separator.
2.5.1 Safety precautions for transport

• For loading and unloading operations, use only hoists and load carrying
equipment with adequate lifting power (the weight of the centrifugal mixer is
specified in the documentation, the dimensioned drawing or a data sheet fur-
nished with the documentation).
When transporting and assembling machine parts:
Danger of squashing!
CAUTION!
• Lift the machine correctly only in accordance with the specifications in the
user information (lifting points etc.) using a hoist!
• Do not use damaged or incomplete load carrying equipment.
• Appoint a competent instructor for the lifting process!
• When using load carrying equipment and hoists, observe the statutory regula-
tions and safety regulations.
• Use only a suitable transport vehicle with adequate lifting power!
• Reliably secure the load. Use suitable lifting points.
• After loading, provide the machine with devices which prevent a shift in posi-
tion (sliding, moving).
• Observe the regional regulations and laws.
8090-9001-100 / 0306
2.5.2 Special risks of a centrifugal mixer

The centrifugal mixer is equipped with a high-speed rotating metal bowl which
represents a danger potential not to be underestimated on account of the rota-
tional energy which can pose a danger for the installation and persons working
in the installation when not properly handled.
Switch off the centrifugal mixer before carrying out maintenance or repair
work.
Wait, observe and check that all rotating parts are at a standstill.
Do not reach into the rotating drive section or bowl!
CAUTION! Do not loosen any part before the bowl has come to a standstill!
Risk of injury and danger to life through rotating parts.
The following options are available for checking standstill on centrifugal mixers
depending on the version:
• Fan wheel on motor
Visual rotation check on centrifugal

mixers
You can observe whether the machine

is at a standstill at the point marked
with the arrow.
We reserve the right to carry out de-

sign modifications.
Fig. 9 8090-Centrifugal mixer
During cleaning programs (e.g. CIP), very high temperatures are reached on the
surfaces of the centrifugal mixer and piping.
During cleaning programs, the surfaces of the centrifugal mixer and pipes
are very hot.
CAUTION! Danger of burns!
When the noise level of the centrifugal mixer is too high, noise-dampening
ear protectors must be worn.
CAUTION! Danger of hearing damage!
8090-9001-100 / 0306
During all maintenance and repair work on the centrifugal mixer, the fit-
tings and pipes, hot, caustic liquids may spit out under excess pressure.
Danger of cauterisation of skin and eyes!

CAUTION!
2.5.3 Special product hazards

• In the case of products which have to be allocated to a specific hazard class,
adhere to the corresponding local safety precautions when handling these
products.
• Follow the local plant instructions and wear the required protective gear.
• In the event of accidents, keep to the local rules of conduct when handling
products of the respective hazard classes and take appropriate first-aid
measures when injury is involved.
• If necessary, notify the in-house task forces immediately when an accident
occurs (fire-brigade, medics, plant security, disposal teams etc.) so that fur-
ther action can be taken.
8090-9001-100 / 0306
2.5.4 Safety precautions for operating the centrifugal mixer with hazard-
ous materials
Extra special care must be taken when working on centrifugal mixers that are
processing caustic substances such as acids and lyes or other dangerous prod-
ucts.
Machines that are operated with caustic substances are marked with the follow-
ing safety sticker.
Caution!
Wear protective equipment whenever working on the centrifugal mixer.
Caustic substances can be a risk to life and limb and cause damage to ma-
chines and installation plants.
Danger of injury through caustic substances!

The stickers must always be in perfect condition.
• Clean dirty stickers.
• Replace damaged stickers.
In addition to observing the standard safety precautions that apply when work-
ing on the centrifugal mixer, protective equipment must be worn when working
on centrifugal mixers fed with dangerous products to avoid injuries.
Protective equipment consists of, for example:
– Face screen
– Protective suit
– Protective gloves
– Protective boots
NOTE – Apron, etc.
8090-9001-100 / 0306
2.5.5 Special hazards caused by cleaning liquid
Only those chemicals may be used for the chemical cleaning process (CIP)
which are specified in the user information or a datasheet issued with the user
information.
High temperatures are reached during cleaning! Surfaces of hood and

pipes are hot!
Danger of burns!
CAUTION!
• Follow the local plant instructions and wear the required protective gear.
The cleaning media are acids and caustics which can cause severe per-
sonal injury when used without due care.
Danger of acid and alkali burns!

CAUTION!
• Keep to the local procedures when handling acids and lyes to avoid accidents
and take appropriate first-aid measures if injuries do occur.
• If necessary, notify task forces immediately when an accident occurs (fire-
brigade, medics, plant security, disposal teams etc.) so that further action can
be taken.
CIP, in particular the subsequent flushing, must be carried out in accor-

dance with the instructions in the manual.
Danger for centrifugal mixer, gaskets and product
Attention!
• Chemicals not specified / approved by Westfalia Separator and false concen-

trations can result in damage due to corrosion. The corrosion can occur both
on bowl parts as well as on the hood and the concentrate collector.
• The bowl gaskets can swell as a result of inadequate flushing.
• Inadequate flushing can also lead to chemical residues entering the product
rendering it useless.
8090-9001-100 / 0306
2.5.6 Steam sterilization

Machines which are designed for steam sterilization may only be sterilized with
hot steam when the machine is at standstill.
Maximum steam overpressure: See boilerplate
Product-carrying chambers of steam-sterilizable machines are pressure

vessels. No welding or metal-cutting may be carried out on them. (When
repairs are needed, contact the factory).
CAUTION!
• To prevent burns:
– Cordon off the machine and steam-carrying plant components to prevent
persons coming into contact with them (chains, barriers, information signs
etc.).
– Attach a yellow warning light that blinks to indicate that the sterilization is in
progess.
8090-9001-100 / 0306
2.5.1 Hazard due to explosive materials (Ex-zone)

A centrifugal mixer may only be operated in a potentially explosive zone when it
is suitably rated for this purpose. Combustible liquids or liquids out of which
combustible gases or vapours can be liberated may only be processed with
suitably designed centrifugal mixers. The markings on the centrifugal mixer indi-
cate whether a centrifugal mixer is suitable or not.
In this connection, the operator must observe the local statutory regulations. In
Europe, these are in particular the Directives 1899/89/EG and future follow-up
versions.
Within the meaning of the Directive 94/9/EG, an explosive atmosphere is de-

fined as a mixture of combustible materials in the form of gases, vapours, mists
or dust and air under atmospheric conditions, in which the combustion process
after ignition can spread to the entire nonburned mixture.
Due to local on-site conditions, the atmosphere can become explosive in the
centrifugal mixer (bowl-hood, gear chamber) or in the environment of the cen-
trifugal mixer.
Centrifugal mixers and protective systems may only be used in such an explo-
sive atmosphere (Ex-zone) which have been designed and manufactured in ac-
cordance with the latest knowledge in the field of explosion protection so that
they can be safely operated during the course of their expected lifecycle. The
locally valid guidelines and regulations governing explosion-proof zones must
be observed.
Components and spare parts for installation in the centrifugal mixer and its pro-
tective systems are designed and manufactured so that they can be safely used
for the application in explosive atmospheres when fitted by trained personnel in
accordance with the mounting instructions. Therefore, only genuine original
spare parts may be used.
The air needed to create an explosive atmosphere in a closed system such as a

centrifugal mixer can be displaced by inert gas (e.g. nitrogen). Subsequently,
the penetration of atmospheric air must be prevented by constant overpressure.
• The centrifugal mixer has been rated by the manufacturer in accordance with
the specifications of the operator. The operator is responsible for the correct-
ness of these specifications.
• All electrical equipment used in conjunction with the centrifugal mixer such as
motor controls, valve controls, electric heaters etc. must be in explosion-proof
design. Equipment which is not in explosion-proof design must be installed in
a non-explosion-proof zone.
• Protective measures in line with primary explosion protection (ventilation etc.)
must be carried out in the immediate vicinity of the centrifugal mixer.
8090-9001-100 / 0306
Operation of the centrifugal mixers in areas categorised as “Zone 0”, i.e.

in areas in which dangerous, explosive atmospheres are present con-
stantly or for prolonged periods is prohibited.
Explosion risk!
CAUTION!
The operator of the machine or plant is therefore obligated to determine

the so-called zone or have it determined by an authorised body.
Further information is given in the ATEX Directive 94/9 EU and follow-up ver-
NOTE sions.
8090-9001-100 / 0306
2.6 Additional notes
2.6.1 Operating principles

Centrifugal mixers are used for mixing liquids.
High centrifugal forces are produced in

the rotating bowl of the centrifugal
mixer. These are used to mix liquids of
different density and consistency.
The stability of the liquid produced in

this way depends on the initial prod-
ucts and the further processing.
Fig. 10
2.6.2 Bowl speed and product

The bowl speed is an important parameter when rating the centrifugal mixer. It
depends on the chemical and physical properties of the product such as
• Temperature
• Density of the fluid and solid components
• Aggressiveness of the product as regards corrosion and erosion (influences
the selection of the bowl material).
The bowl speed is determined on the basis of these parameters allowing for an
adequate safety margin.
Before using a product with properties different from those stated when placing
the order, it is imperative to obtain the manufacturer's approval.
2.7 Working on the machine / regular checks

The machine works safely and reliably, provided that it is operated and main-
tained in accordance with our operating instructions.
The operator must ensure that the machine is checked by qualified per-
sonnel for operational safety at least once a year in operating state and,
additionally, in dismantled state as required, but at least every 3 years.
Shorter intervals must be defined when processing corrosive or erosive
NOTE products.
Special attention must be given to:

• Assembly
• Start-up
8090-9001-100 / 0306
• Repair
2.7.1 Assembly
• If the plant has several centrifugal mixers, be careful not to interchange parts
of different bowls since each bowl has been balanced individually.
• The parts are marked with the serial-number of the machine or with the last
three digits of the serial number.
• Replace damaged parts by new or reconditioned parts.
• After installing certain critical spare bowl parts, the bowl must be re-balanced.
(for further details, see bowl assembly)
• Some bowl parts must be arranged in fixed positions relative to one another.
• Locking devices and alignment marks must be in perfect condition.
• Otherwise, the bowl may not be operated.
• When assembling the bowl, be sure to strictly adhere to the instructions given
in chapter "bowl", in order to avoid undue unbalance.
• Before starting the bowl, be sure to fit all parts.
• 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. (for further details,
see bowl assembly)
• Check if the centrifugal mixer is

completely assembled and properly
installed.
• Carefully secure hood 1 and con-
nections 2.
Fig. 11
8090-9001-100 / 0306
2.7.2 Before start-up
• Check that the supervisory equip-

ment is operational and the correct
limit values are adjusted.
• When hoods are pressurized, e.g.
by
inert gas,
the pressures stated on the name-
plate must not be exceeded.
Fig. 12
• Check that the product lines are set

to operation.
• Regularly check hoses for signs of
ageing.
• Check sight glasses for mechanical
damage.
• Replace damaged parts by new or
reconditioned parts.
Fig. 13
8090-9001-100 / 0306
2.7.3 Safety precautions for start-up

• Check that all screwed connections are tight.
• Check that the lock rings on the

bowl.
Fig. 14
• Follow the instructions on bowl assembly in the chapter Maintenance and

repair.
• The direction of rotation of the bowl

must correspond to the direction of
rotation arrow on the frame or solids
catcher.
The direction of rotation of the bowl

is normally clockwise when looked at
from above.
• The centrifugal mixer may only be operated with protection devices conform-
ing to EN 294.
• Carry out all testing and checking operations in accordance with the commis-
sioning instructions in the instruction manual.
8090-9001-100 / 0306
2.7.4 Start-up
• Refer to chapter ”operation”.

Manufacturer’s nameplate • Note manufacturer’s nameplate.
The values for
– bowl speed
– density of the heavy liquid,
– density of solids (centrifugally dry)
are maximum values and must not
be exceeded.
Fig. 15
2.7.5 Safety precautions for operation

• Never carry out work on the centrifugal mixer when the bowl is rotating.
• Do not loosen any part before the bowl has come to a standstill!
• When unusual noises or vibrations occur, press EMERGENCY-OFF immedi-
ately and leave the danger zone.
When unusual noises or vibrations occur:
– Evacuate the room!

– Do not enter the room again until the bowl has come to a standstill!
CAUTION!
Danger to life and limb through machine parts being thrown around!
• When operating the centrifugal mixer without slide-ring packing, the bowl
must not run for longer than 15 minutes without liquid supply as otherwise
overheating of the bowl material may occur.
• In the case of operation with a slide-ring packing the centrifugal mixer must
be shut down during every interruption in production as otherwise the slide-
ring packing would be destroyed and leaky. A slide-ring packing must never
be operated without liquid.
8090-9001-100 / 0306
2.7.6 Safety precautions for maintenance and repair

• Observing the maintenance intervals and user information is decisive for the
service life and permanent operating readiness of the centrifugal mixer.
• The maintenance intervals depend on the operating conditions. Especially
highly stressed parts of the centrifugal mixer must be regularly checked.
Adapt the maintenance intervals to the operating conditions!
• Timely maintenance of the centrifugal mixer is essential for safe operation.
Especially highly stressed parts of the

centrifugal mixer such as
– Bowl lock ring
– Bowl bottom,
– Bowl top
must be regularly checked (at least
once a year) as specified in the main-
tenance schedule to assure safe and
efficient operation.
Fig. 16
When carrying out maintenance and repair work:

• Do not climb onto the centrifugal mixer or stand on parts of the ma-
chine!
Danger of injury through slipping or falling down!
• Repairs to the centrifugal mixer may only be carried out by service techni-
cians from Westfalia Separator or personnel trained and certified by Westfalia
Separator.
• During maintenance and repair work, make sure that the main switches are
switched off and secured against restarting.
• Make sure that other persons do not have the possibility to start the machine
before the maintenance or repair work is finished.
• Make sure that the rotating parts of the centrifugal mixer (motor, bowl) are at
a standstill before carrying out maintenance and repair work.
• When the machine is defective, a warning sign must be attached and the cen-
trifugal mixer must be secured against unauthorized starting.
8090-9001-100 / 0306
• Do not heat bowl parts with a

naked flame to facilitate disman-
tling work.
Structural changes in the material of
the bowl parts which affect the operat-
ing safety of the machine may result!
• Do not weld bowl parts.
Fig. 17
• Do not weld hood and solids catcher parts of steam-sterilizable centrifugal

mixers.
• Place the dismantled centrifugal mixer parts on suitable surfaces (rubber,
wood etc.).
• Take appropriate steps to prevent parts of the centrifugal mixer from over-
turning and rolling away.
• When carrying out assembly work on several centrifugal mixers, be careful
not to interchange parts of different bowls! Each bowl must be balanced with
its respective components.
The parts are marked with the serial-number of the machine or with the last
three digits of the serial number.
• Some bowl parts must be arranged

in fixed positions relative to one an-
other.
• Locking devices and alignment
marks must be in perfect condition.
The centrifugal mixer may not be op-

erated when locking devices and
marks on the bowl parts are damaged.
Fig. 18
• After fitting certain bowl parts (e.g. bowl bottom, bowl top) the bowl must be
re-balanced.
Bowl balancing may be carried out only by specialists from Westfalia
Separator or specialist workshops authorized by Westfalia Separator!
If in doubt, consult the service department of Westfalia Separator.
8090-9001-100 / 0306
• Do not manipulate speed-altering devices such as frequency converters so

that the maximum admissible bowl speed (see nameplate or “technical data”
in the instruction manual) is not exceeded.
• Ensure that monitoring devices (e.g. overspeed monitors etc.) are not ma-
nipulated or damaged and check their function in accordance with the instruc-
tions in chapter “Maintenance and repair – maintenance schedule”.
• When carrying out maintenance and repair work, carry out a visual check of
the centrifugal mixer components. Have the components checked for damage
through corrosion and erosion by authorized specialists and proceed in
accordance with the instructions in chapter “Maintenance and repair – in-
spections”.
The centrifugal mixer must be shut down immediately when damage due
to corrosion or erosion is detected!
There is a risk of damage to the centrifugal mixer and a danger to life and
Caution limb of the user through machines parts flying around!
In case of doubt, contact Westfalia Separator!
• After maintenance and repair work on the centrifugal mixer, refit all protective
devices.
8090-9001-100 / 0306
2.7.7 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 using non-

destructive techniques. At the initial stage pitting corrosion is generally caused
by chlorine ions.
Depending on the stressing of the part, pitting corrosion can result in crack for-
mation.
Possible formation of pitting corrosion.
Fig. 19
Such pittings can only be investigated by a materials expert.
In case of crack-shaped corrosion attack on bowl parts with or without super-

posed flat-spread and pit-shaped corrosion, the centrifugal mixer must be
shut down immediately.
Contact your nearest Westfalia Separator representative for a thorough exami-

nation.
8090-9001-100 / 0306
Pittings
Such pittings should be investigated
by a materials expert.
Pittings which are close together or
form a linear pattern can signify crack
formation beneath the surface.
Fig. 20
Signs of corrosion which you should

immediately report to your nearest
Westfalia Separator representative:
• The bottom of the corrosion mark
has a radius smaller than 1 mm
(large notch effect).
• The depth of corrosion mark ex-
ceeds 1 mm at the deepest point.
2.7.8 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 high-stressed bowl material.
Contact your nearest Westfalia Separator representative for a thorough exami-

nation. Information on the nature of the damage can be provided in the form of
photos, plaster casts or lead molds.
8090-9001-100 / 0306
Fig. 21
The surfaces most susceptible to erosion are:

1) Centrifugal mixer bowl
2) the centripetal pump (cavitation),
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 at the deepest point.
Fig. 22
2.8 Sight glasses
When the wall thickness of a sight glass or sight glass housing has de-
creased by more than 10 %, the centrifugal mixer may not be operated
again until the sight glass and / or sight glass housing have been re-
placed.
NOTE
Consequently, all sight glasses in the feed and discharges of separators as well
as all other sight glasses in its environment must be checked for wear on a
regular basis. More detailed information on this is given in the DIN standards
7097 and 7080.
8090-9001-100 / 0306
2.9 Prior to a long-term shut-down

• Clean bowl thoroughly.
• The clean bowl parts and all unvarnished machine parts must be wiped dry
and greased to avoid corrosion.
• Check water shut-off devices for leakage.
• If necessary, disconnect water supply lines to avoid damage caused by drip
water.
• Switch off operating water supply at the mains to prevent inrush of water
caused by inadvertent opening of the shut-off valve.
• Protect the drive spindle and motor against dust and vibrations.
• Corrosion protection must be carried out in accordance with the instructions in
the documentation.
• Remove and place all gaskets in storage.
8090-9001-100 / 0306
2.9.1 Final decommissioning

When decommissioning the machine:
• Disconnect all electrical connections.
• Dismantle all product and operating water feed and discharges.
• For dismantling the machine, use only hoists and load carrying equipment
with adequate lifting power (the weight of the machine is specified in the
documentation or a data sheet furnished with the documentation).
• The machine may have to be dismantled for transport, e.g. a centrifugal mixer
may only be transported with dismantled bowl.
When transporting and assembling machine parts:
Danger of squashing!
CAUTION!
• Lift the machines correctly only in accordance with the specifications in the
user information (lifting points etc.) using a hoist!
• Do not use damaged or incomplete load carrying equipment.
• Appoint a competent instructor for the lifting process!
• When using load carrying equipment and hoists, observe the statutory regula-
tions and safety regulations.
• Use only a suitable transport vehicle with adequate lifting power!
• Reliably secure the load. Use suitable lifting points.
• After loading, provide the machine with devices which prevent a shift in posi-
tion (sliding, moving).
8090-9001-100 / 0306
2.9.2 Disposing of the machine
Observe the disposal concept valid for the plant and the plant procedure for dis-
posal issued by the operator as well as the applicable local disposal regulations.
– If applicable, drain lubricating oils and dispose of them in accordance with
local regulations.
– Dismantle all gaskets and non-metallic materials, clean them to remove lu-
bricants and dispose of them separately or send them for recycling.
– Separate the metal parts by sorts and send them for recycling.
The statutory environmental protection regulations must be observed.
2.9.3 Disposal of cleaning liquids

Only those chemicals may be used for the chemical cleaning process (CIP)
which are specified in the user information or a datasheet issued with the user
information.
The cleaning media are acids and caustics which can cause severe per-
sonal injury when used without due care.
Danger of acid and alkali burns!

CAUTION!
Observe the plant procedure issued by the operator on handling acids and
caustics as well as the local disposal regulations.
The statutory environmental protection regulations must be observed.
8090-9001-100 / 0306
Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
8090-9001-100 / 0306
3 Machines in explosion-hazarded zones
3.1 Instructions for the operator................................................................... 54

3.1.1 Machines in explosion-hazarded zones ................................................ 55
3.2 Machine protection concepts ................................................................. 56
3.2.1 Inerting machine chambers ................................................................... 57
3.2.2 Measures when using inerting systems................................................. 57
3.3 Requirements to be met by the inert gas system .................................. 59
3.3.1 Classifying the machines ....................................................................... 59
3.3.2 Applicable standards, regulations.......................................................... 59
3.3.3 Overview schematic centrifugal mixer ................................................... 60
3.3.4 Operating modes “purging and operation”............................................. 60
3.3.5 Inerting the centrifugal mixer ................................................................. 62
3.3.6 Calculating the purging time .................................................................. 63
3.3.7 Flow measurement ................................................................................ 64
3.3.8 Monitoring drive components ................................................................ 64
3.4 Installation and adjustment .................................................................... 65
3.4.1 Electrical installation .............................................................................. 65
3.4.2 Rating the inert gas line ......................................................................... 65
3.5 Commissioning ...................................................................................... 67
3.5.1 Start-up and operation ........................................................................... 67
3.5.2 Start-up with automatic purging............................................................. 67
3.5.3 Note on start-up after an interruption in production............................... 67
3.5.4 Operation monitoring ............................................................................. 67
3.5.5 Shut-down.............................................................................................. 67
3.5.6 Opening the machine............................................................................. 68
3.6 Maintenance .......................................................................................... 68
3.7 Spare parts ............................................................................................ 68
8090-9001-100 / 0306
Applications and measures
3.1 Instructions for the operator
Be sure only to use centrifugal mixers designed for operation in poten-

tially explosive areas.
Never use a centrifugal mixer installed in a potentially explosive area
without having taken adequate explosion-prevention measures.
CAUTION! Risk of deflagration or explosion by formation of explosive gas mixtures
in the presence of an ignition source.
The operator has to make sure that for all measures necessary to use a cen-
trifugal mixer in an explosion-hazarded zone are taken.
For operation of the centrifugal mixer in an explosion-hazarded zone, we rec-
ommend installing an inerting system from Westfalia Separator.
NOTE
In this chapter you will find information on the installation and operation of the
centrifugal mixer in explosion-hazarded zone when no inert gas blanketing sys-
tem is included in the delivery scope of Westfalia Separator.
If an inert gas blanketing system is included in the delivery scope, be sure to

pay attention to the enclosed inert gas blanketing manual.
This chapter or the manual of the inert gas blanketing system contain instruc-
tions and information which must be followed in addition to the others in the cen-
trifugal mixer manual. They deal especially with the operation of machines or in-
stallations in the explosion-hazarded zone.
For more in-depth information or in case of open questions, please con-

tact on of our sales agencies or authorised representatives in your region.
NOTE
8090-9001-100 / 0306
3.1.1 Machines in explosion-hazarded zones
If a centrifugal mixer is used in an explosion-hazarded zone, it must be specially

designed and equipped for this purpose.
The designation of such a mixer according to RL 94/9/EG contains an important
reference to the special application conditions to be observed in the form of an
appended X, e.g.
Ex II 2 G T4 X
The instruction manual / user information for this machine is likewise provided
with the corresponding mark and addresses these conditions in more detail. The
machines must normally be blanketed with inert gas.
Depending on the machine type, the design and the product processed, other
protection concepts can be realised instead of blanketing with inert gas.
If inert gas blanketing of the centrifugal mixer can be dispensed with due to the
product to be processed and an alternative protection concept is admissible
(e.g. “venting concept”) the field of application of the centrifugal mixer is se-
verely restricted. In particular, only those products specified by Westfalia Sepa-
rator may be processed in this centrifugal mixer that are described under “Cor-
rect usage” in the complete documentation (user information in accordance with
EN 12547).
Further information can be found in the machine designation on the nameplate.
If the first of the three final digits is a 5 (e.g. ABC xxx.-.xx.-5xx) the centrifugal
mixer has been constructed for explosion protection by means of inert gas blan-
keting.
If a digit other than 5 is specified (e.g. ABC xxx-xx-1xx), alternative protection
concepts (e.g. venting concept) can be used with the above-mentioned restric-
tions.
In both cases, the centrifugal mixer is marked for application in explosion-
hazarded zones (e.g. Ex II 2 G T4 X). The “X” in the designation is a reference
to the information on the special application conditions in the user information.
If in doubt, contact Westfalia Separator before planned changes in the applica-
tion.
8090-9001-100 / 0306
3.2 Machine protection concepts

In explosion-hazarded zones, the operation of machines poses a heightened
safety risk due to the possible formation or presence of explosive gas mixtures.
Application of the guideline minimises the risk of ignition of explosive mixtures.
The following core points form the basis for safe operation of the centrifugal
mixer in explosion-hazarded zones.
• Application of EN 13463-5 (constructional safety)
All mechanical equipment is designed for safe operation in explosion-
hazarded zones.
• Use of electrical apparatus that is approved for use in explosion-hazarded
zones.
Depending on the machine type, the design and the product processed,
other protective concepts can be realized on the centrifugal mixer than
inert gas blanketing such as venting the hood chamber outside explosion-
NOTE hazarded areas.
• Inerting
When a product is processed which can form an explosive gas mixture in the
machine due to vapour formation or gas evolution with the oxygen, the ma-
chine must be inerted.
Through inert gas blanketing, the oxygen level in the machine interior is re-
duced to such an extent that no explosive gas mixture is present.
Slight excess pressure inside the machine prevents atmospheric oxygen from
entering the machine.
• Depending on the machine type, drive concept and installation site, the frame
and / or drive chambers are inerted in addition to the product chamber (see
section “Overview schematic centrifugal mixer”).
• Drive with frequency converter
If the centrifugal mixer is driven with the aid of a frequency converter (FC), an
independent speed limiting device must prevent an admissible speed. The
monitoring device shuts down the machine as soon as a pre-set threshold
value is exceeded.
When a ready-to-operate machine with control system is delivered by

Westfalia Separator, the above fail-safe control and monitoring devices
fulfil the criteria specified in EN 954-1 from the sensor right up to the
evaluation and switch-off chain.
NOTE
In the case of provision by the customer, the general contractor must ensure
that the rules are complied with within the meaning of the Machinery Directive
and that category 2 of the harmonised standard is realized.
8090-9001-100 / 0306
3.2.1 Inerting machine chambers

The formation of explosive mixtures can be prevented by adding gaseous inert
gases such as nitrogen, carbon dioxide, water vapour.
The inerting process displaces the oxygen in the explosion-hazarded zone.
The essential pre-condition for all types of inerting is monitoring with suitable
measuring instruments. The inert gas flow, for example, ort he oxygen concen-
tration in the machine can be measured.
When the oxygen content in the machine is checked, the measuring instruments
must have been tested for functionality by an approved testing body. This is
sometimes demanded in special specifications.
In the inerting process the critical value for inert gas addition is the oxygen limit
concentration. This means the highest oxygen level for the combustible material
at which flame propagation is no longer possible. This must be differentiated be-
tween the highest possible oxygen concentrations derived from the experimen-
tally determined oxygen limit concentration by deducting a safety margin. In ad-
dition, an alarm threshold must be defined below the highest admissible oxygen
concentration. The characteristics of the monitoring instruments must also be
taken into consideration.
3.2.2 Measures when using inerting systems
When inerting machine chambers, pay special attention to, observe or carry out
the following:
– Selection of suitable variables to be measured (oxygen concentration, inert
gas volume, pressure and/or time)
– Selection of suitable measuring technique
(e.g. measuring principle, error margins, response time of the measuring
instrument, time delay of the indicator caused by the distance between the
measuring instrument and pickup point).
– Selection of the suitable measuring point which, under consideration of the
flow behaviour, registers the least favourable conditions for the oxygen
concentration. Several measuring points may be necessary.
• Appropriate measures must be defined for abnormal occurrences.
– Shutting down the installation in case of a malfunction inerting. Shut-down

should normally be automatic.
– Definition of suitable alarm thresholds at which suitable counter-measures
can be triggered (automatically or mechanically) if exceeded or not
reached.
• In the case of intermittent measurements, it must additionally be ensured that
– completely enclosed systems are available with constantly defined and re-
producible gas flow control (danger: cleaning openings)
– Safe operating conditions have been previously defined for inerting in an
adequately long operating period.
– Whenever modifying the installation, the operating conditions for inerting
must be checked and re-defined.
– the degree of inerting of all relevant plant components is known for all op-
erating states and failure of an inerting agent is signalled by an alarm.
8090-9001-100 / 0306
Non-compliance with these instructions can result in endangering per-

sons, environment and machines and lead to the loss of entitlement to
any damage claims.
NOTE
8090-9001-100 / 0306
3.3 Requirements to be met by the inert gas system
3.3.1 Classifying the machines

The machine is a device within the meaning of the directive 94/9/EC, which be-
longs to the group G II, category 2. The associated temperature class is speci-
fied in the technical datasheet.
3.3.2 Applicable standards, regulations
The following standards, guidelines and regulations must be taken into consid-
eration in respect of the requirements to be met by apparatus used in explosion-
hazarded zones.
• DIN 40050 (IEC 529/144): A protection system in accordance with DIN 40050
(IEC 529/144) must be selected for the electrical apparatus which suits the
environmental conditions.
• VDE 165: When installing intrinsically safe electric circuits, observe the regu-
lations as per VDE 165.
• EN 1127-1: Explosive atmospheres-explosion protection, Part 1 “Fundamen-
tals of methodology”
• EN 50018: Electrical apparatus for use in explosion-hazarded zones / flame-
proof enclosure “d” EN 50020.
• EN 50019: Electrical apparatus for use in explosion-hazarded zones / in-
creased level of safety “e” in EN 50019.
• EN 50020: Electrical apparatus for use in explosion-hazarded zones / inher-
ent safety “I” EN 50020.
• EN 60079-14: Electrical apparatus for explosion-hazarded zones in accor-
dance with EN 60079-14.
• EN 13463-1: Non-electrical devices for use in explosion-hazarded zones, Part
1: “Fundamentals and requirements”.
• EN 13463-5: Non-electrical devices for use in explosion-hazarded zones,
Part 5: “Protection through safe construction”.
• EN 954-1: EN 954-1 provides support when selecting safety-related parts of
control systems.
– The electrical components of an inerting system must have been approved

for operation in explosion-hazarded zones in as far as they are installed in
these areas. The monitoring devices with the corresponding switch-off chains
NOTE must satisfy the requirements of category 2 / EN 954-1.
– The control unit can be integrated in the supply system on site in the explo-
sion-hazarded zone.
– The operator is responsible for application of the apparatus.
8090-9001-100 / 0306
3.3.3 Overview schematic centrifugal mixer
Fig. 23
1) Hood chamber
The inerting system can be used to purge and blanket the hood chamber, de-
pending on the specific equipment configuration system.
Depending on the machine type and design, direct monitoring of the compo-
nents can be an alternative to inerting (see also section “Protective concept of
the machine”).
NOTE
3.3.4 Operating modes “purging and operation”

During operation in explosion-hazarded zones, the hood chamber of the ma-
chine must be purged with inert gas prior to start-up and blanketed during op-
eration.
In order to assure safe operation, the following monitoring functions must be
available:
• Hood chamber for minimum pressure / minimum flow.
• If the pressure drops below the minimum pressure, safe operation of the ma-
chine cannot be assured. An alarm must be triggered and the machine shut-
down. During shut-down, the inerted chambers are purged.
In the case of a drop in pressure, there is no immediate danger through explo-

sive atmosphere. Safe shut-down is possible.
NOTE
• Hood chamber for minimum flow during purging.
8090-9001-100 / 0306
• Monitoring of time. Monitoring of the pressure for plausibility.

• If the flow rate, time or pressure drop below their minimum levels, an alarm
must be triggered and the program step “purging” must be aborted. The ma-
chine cannot be aborted.
• Hood chamber for maximum flow during blanketing.
• If the maximum flow rate is exceeded an alarm can be triggered to indicate
excessive nitrogen consumption to the operator.
• During commissioning and after modification of the installation: After purging,
the customer must measure the oxygen level in the inerted chambers.
The blanketing pressures with inert gas depend on the type of machine. They
are specified in the corresponding installation diagrams.
8090-9001-100 / 0306
3.3.5 Inerting the centrifugal mixer

The hood chamber must be inerted before feeding easily flammable product to
the centrifugal mixer. It is essential to pay attention to the following points:
• When a “control unit for inert gas” (inerting system) is included in the supply
schedule, the manual furnished with the inert gas blanketing system is bind-
ing!
• Determine the highest admissible oxygen level in the three-component sys-
tem inert gas-oxygen-fuel for the combustible liquid to be processed (if nec-
essary, contact the supplier).
The oxygen must be reduced to a level at which ignition is not possible.
The natural O2 concentration in the air is 21 %. After n-times gas exchange
with inert gas the O2 concentration falls as follows:
21 %
O2-Konzentration = ––––
2n
Gas exchange n = 1 produces a O2 -concentration: 10,50 %

In the case of gases and vapours which are ignitable up to an oxygen concen-
tration of 5 % in the gas mixture, e.g. hydrogen, a three-times gas exchange
would theoretically be possible.
For safety reasons, e.g. due to possible measuring errors, diffusion gaps and
small leakages, it is recommended to displace the chamber to be blanketed with
5-times its volume of inert gas.
Nitrogen quality
The purity of the nitrogen must be at least 99 %.
The admissible dew point should not exceed 60°C to –80°C.
Nitrogen which is too dry shortens the service life of the machine seals.
8090-9001-100 / 0306
3.3.6 Calculating the purging time
Purging is normally carried out automatically (purging program).
Calculating the purging time
n x V x 60
t = ––––––––––––– [min]
Qmax
t = Purging time [min]

N = Number of gas exchanges
V = Volume of the complete chamber with all connected chambers [l]
The gas volume is specified in the P&ID. The volume of adjacent chambers
must be determined.
Qmax = Throughput capacity during purging [l/h].
The reading is shown on the flowmeter (if necessary, calculate real flow rate).
Pre-conditions for a correct reading:
– The system pressure is maintained.
– The throttle valve is adjusted to the correct capacity.
• Purge the hood chamber of the centrifugal mixer with a suitable inert gas.
– Work with the maximum inert gas throughput capacity (Qmax).
– Purging of the inerted chambers should be carried out with a slight over-
pressure of 0.03-0.04 bar at the overpressure vent.
• Measure the oxygen concentration in the inerted chambers in order to check
the inerting result.
This ensures that the installation is suitable to adequately inert the centrifugal
mixer and that the purging time is long enough.
Oxygen measurement is required prior to the first start of the centrifugal mixer
and after modification work.
• During run-up of the centrifugal mixer and up to a stable production mode, the
centrifugal mixer should continue to be purged with the maximum inert gas
capacity.
8090-9001-100 / 0306
3.3.7 Flow measurement
Since gas is compressible and hence the volume V depends on the pressure p
and temperature T, the flow rate measured by the flowmeters used is only valid
at calibration pressure and calibration temperature.
The flow rate is indicated in Nm³/h.
If the pressure and/or temperature parameters change, the deviation of the real
flow rate from the measured flow rate is produced in accordance with the state
of equation for ideal gases.
p x v = R x T
p = Pressure in Pascal
v = Volume in m3
R = 296.78 (gas constant for nitrogen)
T = Temperature in Kelvin
In the event of deviating pressure conditions and constant temperature, the real
flow rate is altered as follows:
1,013 + real pressure

real throughput = ------–––––––––––––––- x measured throughput
1,013 + cal. pressure
meas. = measured
cal. = calibrated (e.g. flowmeter: 2 bar at 20°C)
3.3.8 Monitoring drive components
If the drive components are monitored directly instead of inerting the drive
chamber, these monitoring systems must fulfil the specifications of EN 954-1,
category 2.
NOTE
8090-9001-100 / 0306
3.4 Installation and adjustment
3.4.1 Electrical installation

To shut down the machine in an emergency, a “standstill in emergency” control
switch in accordance with EN 60204-1 must be installed at an appropriate point.
3.4.2 Rating the inert gas line

When rating the inert gas supply lines, special attention must be paid to the
pressure loss in the supply lines.
Pressure loss
To avoid sharp pressure drops, the control unit must be installed as close as
possible to the centrifugal mixer.
The largest inert gas volume streams in the supply line occur when purging the
inerted chambers.
The formula below can be used to calculate the pressure drop in the supply line:
1,6 × 10 8 × V 1,85 × L
dp = [bar ]
d 5 × pl
dp = Pressure drop [bar]

V = Throughput capacity [m3/s]
d = Inner diameter [mm]
L = Nominal length of the pipe [m]
pl = Working pressure [bar]
8090-9001-100 / 0306
The diagram “Pressure loss in the nitrogen line to the machine” shows by way of
example the dependence of the pressure loss on the length of the connecting
lines between an inert gas cabinet and the machine at a throughput of
5400 NL/h inert gas for inner diameters of the connecting lines of 6 mm, 9 mm
and 12 mm.
Pressure loss in the nitrogen line to the machine
Medium nitrogen
Throughput 5400 l/h
Working pressure 2 bar
Pressure loss mbar
Inner diameter 6 mm
Inner diameter 9 mm
Inner diameter 12 mm
Line length m
Fig. 24
8090-9001-100 / 0306
3.5 Commissioning
3.5.1 Start-up and operation

Before starting the drive motor, the hood chamber of the centrifugal mixer must
be purged with inert gas.
The purging gas capacity for the hood chamber is adjusted.
The drive motor must not be started until the chamber has been purged with the
five-fold volume of the chamber to be purged.
3.5.2 Start-up with automatic purging

Solenoid valves control the inert gas flow during automatic purging. The purging
times are entered in the purging program.
3.5.3 Note on start-up after an interruption in production

If the pressure has not dropped below the minimum pressure in the inerted
chambers at any time since the machine was last operated, the drive motor
starts without purging time t. Purging is however carrried out during run-up.
3.5.4 Operation monitoring

Perfect operation is monitored as follows:
• A flowmeter monitors the inert-gas stream towards the hood chamber.
• When the preset limit value for maximum flow is exceeded, an alarm is trig-
gered.
• A pressure gauge monitors the hood chamber for minimum pressure.
When the minimum pressure is no longer reached, an alarm is triggered.
The cause of the pressure drop MUST be found out and remedied. Otherwise:
Leakages arising from the vacuum developing inside the centrifugal mixer
might cause air to penetrate into the blanketed areas and form an explo-
sive gas mixture.
CAUTION! Together with an ignition source, this can lead to a deflagration or explo-
sion.
If after purging, the minimum pressure is reached again, the operation of the
centrifugal mixer will not be interrupted. Otherwise the centrifugal mixer will be
shut down automatically while being purged with inert gas until standstill.
3.5.5 Shut-down
Brief shut-down
Continue to supply inert gas when no repairs are scheduled to be carried out on
the machine.
Given the following conditions, the centrifugal mixer can be re-started without
purging.
• the inert gas supply has not been interrupted
• the connections for the inerted chambers have not been dismantled
8090-9001-100 / 0306
• the minimum pressure for the inerted chambers has not been dropped below
Prior to a long-term standstill (e.g. for repairs)
Let the inert gas supply run for approx. one hour after the bowl has come to a
standstill; otherwise the following problems may arise:
– A vacuum forms in the machine due to cooling off of the bowl, frame and
gas. The water in the immersion vessels (siphons) is sucked into the ma-
NOTE chine creating a connection between hood chamber and atmosphere.
– Air entering the drive or hood chamber causes the 02 concentration to rise.
When the O2 concentration exceeds the maximum admissible value,
an explosive mixture can explode if an ignition source is present.
This can result in injury to persons and damage to property.

CAUTION!
Automatic shut-down
Depending on the equipment configuration, when the machine is switched off

via the speed measuring device or inert gas blanketing monitoring facility (pres-
sure/flow) the machine can run down freely or braked by means of a frequency
NOTE converter.
3.5.6 Opening the machine

When a machine has to be opened, the following points have to be opened:
• Do not loosen any part before the machine has come to a standstill.
• Safety must be assured:
– Standstill is observed
– Nitrogen supply is closed
– Electrical safety is ensured
• Opening the machines can release large quantities of nitrogen or residues of
combustible gases. Take in-house precautionary measures!
3.6 Maintenance
• Carry out daily visual checks for leakage of lubricants or process liquids.
Eliminate leakages immediately to assure safe operation.
3.7 Spare parts

In the case of inerting systems procured from Westfalia Separator, genuine
spare parts from Westfalia Separator fulfil the required specifications.
8090-9001-100 / 0306
4 Machine description
4.1 Application ............................................................................................. 70

4.2 Construction........................................................................................... 70
4.3 Method of operation............................................................................... 70
4.4 Hermetic design..................................................................................... 70
4.5 Feed and discharge ............................................................................... 70
4.6 Materials ................................................................................................ 71
8090-9001-100 / 0306
4.1 Application
Continuous, thorough mixing of liquids of different nature and composition.
Fields of application:
• Food industry
• Chemical and pharmaceutical industries
4.2 Construction
The centrifugal mixer mainly consists of:
• drive motor
• mixer bowl
• housing
• centripetal pump
• slide-ring packing (hermetic design only)
4.3 Method of operation

Two exactly dosed liquids to be mixed are fed to the spinning bowl via the feed
line (see Fig. 25, pos. 1).
In the bowl, they are pared off in a thin layer by the stationary centripetal pump
and thoroughly mixed in its channels.
The mixture is discharged foamfree and under pressure by means of the cen-
tripetal pump.
The centripetal pump converts the rotational energy created by the spinning
bowl into pressure.
This pressure allows the liquid mixture to be conveyed to heights of up to 35
meters. An additional pump for further transportation of the mixture is no longer
necessary.
4.4 Hermetic design

For mixing liquids that tend to oxidize or to evaporate the machine can be fur-
nished in hermetic design.
In this case, the bowl is sealed off hermetically towards the hood by means of a
slide-ring packing (see Fig. 26, pos. 5).
4.5 Feed and discharge

The liquids are fed to the mixer through an enclosed line system.
• The liquid mixture is pressure discharged by a centripetal pump.
• The discharge pressure can be read off from a pressure gauge.
• It is adjusted by means of a throttle valve in the discharge line (pos. 4).
Thus the liquid mixture can be dammed to such an extent that the centripetal
pump channels are immersed in liquid, preventing entrainment of air.
• This design allows
– foamfree discharge of the liquid mixture,
– working without wear-sensitive gaskets.
The discharging mixture can be observed through a sight glass.
8090-9001-100 / 0306
Fig. 25 - ZA -66-905
Fig. 26 - ZA -67-905 (hermetic design)
4.6 Materials
All parts coming into contact with the product (hood, bowl, centripetal pump,
feed and discharge connections) are made of stainless steel.
8090-9001-100 / 0306
Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
8090-9001-100 / 0306
5 Installation
5.1 Installing the mixer in ATEX zone 1....................................................... 75
8090-9001-100 / 0306
Fig. 27
The fitting dimensions and weights are specified in the project-specific dimen-
sioned drawing and the data sheet.
Connections:
1 product feed 4 Nitrogen connection (-505)

Vent (-905)
2 Product discharge 5 Pressure monitoring
3 Frame drain 6 Temperature monitoring
8090-9001-100 / 0306
5.1 Installing the mixer in ATEX zone 1

The dimensions of the mixer are given in the data sheet.
During installation, make sure that:
• there is sufficient space for fitting and removing the bowl.
• the overflow is immersed for the purpose of blanketing with inert gas and that
even so no liquid damming occurs inside the mixer housing.
• the discharge line is fitted vertically upwards on the hermetic version.
• When operating a centrifugal mixer in an explosion-hazarded zone but with a
product that can’t form an explosive mixture through vaporization or out-
gassing with the atmospheric oxygen, the application of a ventilation concept
is admissible. Provision must be made for a continuous air circulation system
that ensures that the air supplied always comes from a non-explosion-
hazarded zone. To meet this demand, also in the event of flow inversion, the
exhaust air must be led into a non-explosion-hazarded room or a vent system.
It is prudent to install the centrifugal mixer on a small firm base.
8090-9001-100 / 0306
Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
8090-9001-100 / 0306
6 Motor connection
6.1 Three-phase AC motor .......................................................................... 78

6.2 Explosion-proof three-phase AC motor ................................................. 79
6.3 Speed of the bowl ................................................................................. 80
6.4 Starting time of the bowl ........................................................................ 80
6.5 Direction of rotation of bowl ................................................................... 80
8090-9001-100 / 0306
6.1 Three-phase AC motor
– All centrifugal mixers are driven by three-phase AC motors.
The technical specifications on the motor supplied are given in the data-
sheets supplied with the documentation, the motor nameplate and / ort he
documentation of the motor manufacturer.
NOTE The switching devices must be rated for the starting current of the motor.
Starting currents
For start-up, the centrifugal mixer requires
– with frequency converter approx. rated current

– with controlled torque approx. 2 – 3 times rated current
Motor protection
• If the motor is equipped with a PTC thermistor, it must be connected to the
corresponding tripping device.
• Lay the measuring circuit line (tripping device-motor) as a separate control
line.
Lubrication
If the motor is equipped with a re-lubricating device, it must be re-
lubricated at regular intervals in accordance with the specifications of the
Attention! motor manufacturer on the motor nameplate.
Motor with frequency converter (FC)

Pay attention to the following when operating the centrifugal mixer with fre-
quency converter:
• The centrifugal mixer must never be started without frequency con-

verter.
Attention!
• The frequency on the frequency converter must be selected so that the

maximum admissible bowl speed is not exceeded. The admissible bowl
speed is indicated on the nameplate of the centrifugal mixer.
The frequency converter is equipped with a frequency limiter to prevent

the admissible bowl speed from being exceeded.
Additionally, a speed sensor is installed on the centrifugal mixer. The lat-
ter transmits the pulses for bowl speed monitoring to the control system.
The control system switches off the centrifugal mixer when the ceiling
speed is exceeded.
The centrifugal mixer may be operated only with this auxiliary device.
NOTE
The ceiling speed must be set to 5% above rated speed (see centrifugal
mixer nameplate).
8090-9001-100 / 0306
Important measures to take during commissioning:

• Check the correct setting of the monitoring devices in accordance with the cir-
cuit diagram and setting instructions.
• Check the speed of the drive spindle:
• Test the safety circuit.
• Attach the following safety stickers and check that they are properly attached
and in good condition:
• Frequency converter operation

• The admissible maximum bowl
speed must not be exceeded.
Fig. 28
• Before carrying out maintenance or repair work on the motor, bear in

mind that there may still be residual voltage.
CAUTION!
In this connection, refer to the documentation of the frequency converter manu-

facturer and have safety measures implemented by suitable personnel.
6.2 Explosion-proof three-phase AC motor
Mixers installed in rooms in which a dangerous explosive atmosphere can occur
are equipped with three-phase AC motors which
• conform at least to the same application category (according to ATEX) as the
mixer.
• are equipped with the prescribed type of protection (according to EN).
It is essential to comply with the provisions of the prevailing local standards
when installing the motor at the site.
8090-9001-100 / 0306
The motor can only be connected to one operating voltage. It is switched on

direct on line.
The motor must be protected by a thermal trip designed in accordance with pre-
vailing standards (under consideration of the directive 94/9 EG) which is ad-
justed to the rated current of the motor.
In the case of operation with a frequency converter, the thermal motor protection
takes the form of temperature probes in the motor (PTC thermistors).
If the switching elements are not in explosion-proof design, they must be in-
stalled outside the explosion-hazarded area.
6.3 Speed of the bowl

For safety reasons, the bowl speed has been rated according to the densities of
the liquids to be mixed.
For densities up to 2.0 kg/dm3, the bowl speed is
– n = 3000 rpm at 50 Hz
– n = 3600 rpm at 60 Hz
In case of higher densities, please check with the factory.
6.4 Starting time of the bowl

The starting time of the mixer is approx. 5 seconds.
6.5 Direction of rotation of bowl

When looking at the motor shaft end, the bowl must rotate in clockwise direc-
tion.
The direction of rotation is indicated by an arrow on the housing.
If it rotates in the opposite direction have two lead-in wires interchanged

by a suitably qualified person.
8090-9001-100 / 0306
7 Lubrication
7.1 Bowl parts .............................................................................................. 82

7.2 Motor bearings....................................................................................... 82
7.3 Sealing rings of the housing .................................................................. 82
8090-9001-100 / 0306
7.1 Bowl parts

Each time when assembling the bowl, grease
– threads and
– guide surfaces of the bowl parts.
The following pastes and greases can be used:
• for mixers used in the food industry:
– Klueber grease KSB 8 (can be used in excess)
• for mixers used in the chemical industry:
– Molykote G
– Molykote G Rapid
Other pastes with the same properties may be used.
7.2 Motor bearings

For lubrication of the motor bearings, refer to the instructions of the manufac-
turer (see motor plate).
7.3 Sealing rings of the housing

The housing of the mixer is sealed off
by two sealing rings.
• The grease chamber between the
sealing rings has to be repacked
with non-corrosive high-melting
point grease every 5 000 operating
hours.
Fig. 29
8090-9001-100 / 0306
8 Bowl
8.1 Important hints ....................................................................................... 84

8.2 Dismantling ( ZA 40 ) ............................................................................. 86
8.3 Assembly ( ZA 40 ) ................................................................................ 88
8.4 Dismantling (ZA 80/100) ........................................................................ 93
8.5 Assembly (ZA 80/100) ........................................................................... 95
8090-9001-100 / 0306
8.1 Important hints

In the bowl rotating at a very high speed, forces are created that are likely to
endanger the operating safety of the mixer if bowl parts are incorrectly fitted or
insufficiently cleaned. Therefore, strictly adhere to the respective instructions gi-
ven in this manual.
In addition, the following must be kept in mind:
• Before fitting bowl parts, thoroughly clean guide surfaces and lubricate them
according to chapter 7.1.
• Check gaskets for wear before inserting them. Make sure that grooves and
gaskets are clean. Use only gaskets that are in perfect condition. After having
inserted a gasket, check to be sure it has not been twisted and is properly
seated in its groove.
• Screwed unions with Teflon gaskets (PTFE) must be tightened firmly to en-
sure proper sealing.
• If the plant has several mixers, do not interchange parts of different bowls
since each bowl has been balanced individually. The parts of each bowl are
marked with the serial number (or its last three digits) of the mixer.
• Bowl parts should always be placed on a rubber mat or a wooden base.
• All bowl parts must be handled with care.
The following chapter gives a description of how to assemble the bowl, the
hood, and the feed and discharge connections.
8090-9001-100 / 0306
Fig. 30
8090-9001-100 / 0306
ZA 40
Exploded view of the bowl

Bowl bottoml
Centripetal pump
Gasket
Gasket
Sealing disk
Gasket
Centrifugal pump
chamber cover
Gasket
Lock ring
Spindle screw
Gasket
85
8.2 Dismantling ( ZA 40 )
Proceed in reverse order of assembly (8.3) bearing in mind the following:

• Switch off main switch and secure with locking device.
• To avoid accidents, do not loosen any part before the bowl has stopped
completely!
CAUTION Only when the shaft end at fan cover of motor no longer rotates is the
bowl at a standstill.
• If bowl lock ring is jammed tight (e.g. after too long an operating pe-
riod), it can be heated with hot water or steam.
Never use other sources of heat!
ATTENTION
• Handle bowl parts with care.
• Be sure to replace worn gaskets immediately.
• Remove feed and discharge con-
nections.
• Remove hood.
Fig. 31
• Before opening the bowl,

– mount bowl locking devices 1 and
– turn bowl lock screws 2 slightly
into recesses of bowl bottom.
• Loosen bowl lock ring by hitting
handle of annular wrench lightly with
a mallet (left-hand thread).
Fig. 32
• Unscrew lock ring 4.

• Remove centripetal pump 3 together
with centripetal pump chamber
cover 2.
Fig. 33
8090-9001-100 / 0306
• Unscrew spindle screw 5.

• Remove sealing disk 2.
Fig. 34
• Slacken back bowl lock screws 2.

• Use jack 3 to force bowl bottom off
the cone of motor shaft.
8090-9001-100 / 0306
8.3 Assembly ( ZA 40 )
• Thoroughly de-grease and wipe
dry the cone of the sleeve fitted on
the motor shaft and the inside of the
bowl hub.
Fig. 35
• Push bowl bottom onto sleeve.

• Mount bowl locking devices 1.
• Turn bowl lock screws 2 into the
recesses of bowl bottom without
applying pressure.
Fig. 36
• Place gasket 1 into bowl bottom.

• Fit sealing disk 2; watch for proper
location.
• Screw in spindle screw 5 tightly
(with inserted gasket 4 and lock
washer 3).
Fig. 37
• Place gasket into groove of bowl

bottom.
• Thoroughly clean and grease
threads of bowl bottom and of bowl
lock ring.
Fig. 38
8090-9001-100 / 0306
• Place centripetal pump 3 together

cover 2 and lock ring 4 against bowl
bottom.
Watch for proper location (bowl bot-
tom/ centripetal pump chamber
cover).
Fig. 39
• Screw on lock ring by hand, left-

hand thread.
• Firmly tighten the lock ring by

hammering with the mallet against
the handle of the ring spanner.
• Slacken back the bowl lock screws
and dismantle the bowl locking de-
vices 1.
• Check the centripetal pump play.
• Check the concentricity of the bowl.
Fig. 40
Hermetic design:
• After having screwed on the lock
ring, slip slide-ring of packing onto
centripetal pump chamber cover
and push it to limit.
• Tighten threaded pin of slide-ring
packing.
Important:
ATTENTION Do not press against the sealing
surface of the slide-ring packing!
Fig. 41
8090-9001-100 / 0306
• Place gasket 1, gasket 2, washer 3

and snap ring 4 into the hood.
Fig. 42
Hermetic design:
• Push counter ring 1 (carbon ring) of
slide-ring packing carefully into head
of hood.
Important:
Do not press against sealing sur-
face of slide ring packing!
Remove slide ring packing only
ATTENTION when it has to be replaced.
• Fasten cover 2 to head of hood with
Allen screws 3.
Fig. 43
• Place hood gasket on contact sur-

face of hood.
• Fasten hood to housing with cap
nuts.
8090-9001-100 / 0306
• Grease the threads on the centripe-

tal pump and in connection piece 1.
• Screw the connection piece on to
the centripetal pump and firmly
tighten with wrench 2 (SW 60) while
holding the feed tube of the cen-
tripetal pump with wrench 3.
• Loosen the two Allen screws, un-
screw them a little way and check
the centripetal pump play.
• The centripetal pump must have a
noticeable play.
Fig. 44 • When there is centripetal pump
clearance, bolt on the hood using all
the fastening screws.
• Screw on the centripetal pump anti-
twist device 5.
• Mount potential compensation 4 of
the hood (hex head screw and
washers) in place of an Allen screw.
• Fit all connections.
8090-9001-100 / 0306
ZA 80/100
Fig. 45
8090-9001-100 / 0306
8.4 Dismantling (ZA 80/100)

Proceed in reverse order from assembly (section 8.3). Observe the following:
Switch off the main switch and lock it.
• To prevent accidents, do NOT loosen any part before the bowl has stopped
completely!
The bowl is not at standstill until the shaft end visible at the fan cover of the
motor has stopped rotating.
If the bowl lock ring is jammed (e.g. after an excessively long operating
time), heat the lock ring with hot water or steam.
Other heat sources may not be used!
• Handle bowl parts with care.
• Replace worn gaskets immediately.
• Dismantle the fittings.
• Remove the hood.
Fig. 46
• Before opening the bowl, unscrew

1 the plug at the recess of the bowl
bottom and lightly screw in the lock
screw 1.
• Loosen the lock ring by rapping with
a mallet against the handle of the
ring spanner (left-hand thread).
Fig. 47
• Unscrew lock ring 4.

• Remove centripetal pump 3 together
cover 2.
Fig. 48
8090-9001-100 / 0306
• Unscrew nut 2.
Fig. 49
• Undo bowl lock screws.

• To force the bowl bottom off the
cone of the motor shaft:
– Use a pulling device.
Fig. 50
8090-9001-100 / 0306
8.5 Assembly (ZA 80/100)

• Carefully remove the grease and
wipe dry the cone of the sleeve on
the motor shaft and the inside of the
bowl hub.
Fig. 51
• Slide the bowl bottom on to the

sleeve.
• Lightly screw in the bowl lock
screws into the recesses of the bowl
bottom.
Fig. 52
• Insert gasket 1 into the bowl bottom.

• Screw on nut 2 tightly with socket
wrench (SW 27).
• Thoroughly clean and grease the
threads on the bowl bottom top and
in the bowl lock ring.
Fig. 53
• Insert gasket 1 in centripetal pump

chamber cover 2.
• Position centripetal pump 3 together
with the centripetal pump chamber
cover and lock ring 4 in front of the
bowl bottom.
Pay attention to correct positioning
(bowl bottom/centripetal pump
chamber cover).
Fig. 54
8090-9001-100 / 0306
• Screw on the lock ring counter-

clockwise by hand.
Fig. 55
• Firmly tighten the lock ring by

1 hammering with the mallet against
the handle of the ring spanner.
• Unscrew bowl lock screws 1 and
replace with a suitable plug and
gasket.
• Check the centripetal pump play.
• Check the concentricity of the bowl.
Fig. 56
Hermetic version:
• After screwing on the lock ring, slide
the housing slide ring of the slide-
ring packing on to the centripetal
pump chamber cover as far as it will
go.
• Tighten the threaded pin of the
slide-ring packing.
Important:
Do not press the sealing surface
IMPORTANT of the slide-ring packing!
Fig. 57
• Fit gasket 1 and gasket 2, disc 3

and snap ring 4 in the hood.
Fig. 58
8090-9001-100 / 0306
Hermetic version:
• Carefully slide the counter-ring 1
(carbon ring) of the slide-ring pack-
ing into the top of the hood.
Important:
Do not press the sealing surface
of the slide-ring packing!
Only dismantle the slide-ring pack-
IMPORTANT ing when it has to be replaced.
• Fasten cover 2 to the top of the
hood with Allen screws 3.
Fig. 59
• Position the hood gasket on the

bearing surface of the hood.
• Fasten the hood to the housing with
2 Allen screws.
Fig. 60
• Grease the threads on the centripe-

tal pump and in connection piece 1.
• Screw the connection piece on to
the centripetal pump and firmly
tighten with wrench 2 (SW 60) while
holding the feed tube of the cen-
tripetal pump with wrench 3.
• Loosen the two Allen screws, un-
screw them a little way and check
the centripetal pump play.
• The centripetal pump must have a
noticeable play.
Fig. 61 • When there is centripetal pump
clearance, bolt on the hood using all
the fastening screws.
• Screw on the centripetal pump anti-
twist device 5.
• Mount potential compensation 4 of
the hood (hex head screw and
washers) in place of an Allen screw.
• Fit all connections.
8090-9001-100 / 0306
Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
8090-9001-100 / 0306
9 Operation
9.1 Before every start-up ...........................................................................100

9.2 Start-up ZA ..-66- .................................................................................101
9.3 Start-up ZA ..-67- .................................................................................101
9.3.1 Shut-down............................................................................................102
9.3.2 Opening the machine...........................................................................103
9.4 Maintenance ........................................................................................103
9.4.1 Maintaining the motor bearings ...........................................................103
8090-9001-100 / 0306
9.1 Before every start-up

Check if
– Allen screws 1 on the hood are
tight.
– The connection piece 2 on the
centripetal pump is tightened.
– The bowl lock screws have been
unscrewed and replaced with a
suitable plug with gasket.
Fig. 62
Note the following for inert gas blanketed machines in the zone ATEX II
2GX:
be purged with inert gas.
The purging gas capacity for the hood chamber is adjusted.
Note the following for vented machines in the zone ATEX II 2GX:
When operating a centrifugal mixer in an explosion-hazarded zone but with a

product that can’t form an explosive mixture through vaporization or outgassing
with the atmospheric oxygen, the application of a ventilation concept is admissi-
ble. Provision must be made for a continuous air circulation system that ensures
that the air supplied always comes from a non-explosion-hazarded zone.
be flushed with air.
Temperature monitoring:
The temperature may not exceed a certain value (see data sheet).
• When operating the centrifugal mixer without slide-ring packing, the bowl
must not run for longer than 15 minutes without liquid supply as otherwise
overheating of the bowl material may occur.
• In the case of operation with a slide-ring packing, the centrifugal mixer must
be shut down during every interruption in production as otherwise the slide-
ring packing would be destroyed and leaky. A slide-ring packing must never
be operated without liquid.
Non-observance of the above will result in overheating of the mixer and

the risk of explosion due to formation of an ignition source.
CAUTION!
8090-9001-100 / 0306
9.2 Start-up ZA ..-66-

• Switch on motor.
• As soon as the bowl has come up to speed (after approx.5 seconds):
feed the liquids to be mixed.
• Adjust the desired throughput capacity.
• Adjust the pressure in the discharge line by means of the throttle valve.
(The backpressure must be below the overflow limit). )
The discharge pressure depends on the throughput capacity.
9.3 Start-up ZA ..-67-

Hermetic version:
• Fill the mixer with liquid until liquid appears in the sight glass.
The bowl must never run without liquid because during dry running the
slide-ring packing wears quickly due to overheating.
Attention!
• Switch on motor.
• Feed the liquids to be mixed as soon as the bowl has come up to speed (after
approx. 5 seconds).
• Adjust the desired throughput capacity.
• Adjust the pressure in the discharge line by means of the throttle valve. (The
backpressure must be below the overflow limit). )
• The discharge pressure depends on the throughput capacity.
The pressure in the discharge line must be adjusted to a minimum of 0.5 bar
to prevent the slide-ring packing from running dry.
Note:
The mixer may only be started with mounted hood.
Caution
8090-9001-100 / 0306
9.3.1 Shut-down
Brief shut-down
Continue to supply inert gas or leave the venting system in operation when no
repairs are scheduled to be carried out on the machine.
Given the following conditions, the machine can be re-started without purging.
• the inert gas supply or fresh air supply have not been interrupted
• the connections for the inerted chambers have not been dismantled
• the minimum pressure for the inerted chambers has not been dropped below
Prior to a long-term standstill (e.g. for repairs)
Let the inert gas supply or fresh air supply run for approx. one hour after the
bowl has come to a standstill; otherwise the following problems may arise:
– A vacuum forms in the machine due to cooling off of the bowl, frame and
gas. The water in the immersion vessels (siphons) is sucked into the ma-
NOTE chine creating a connection between hood chamber and atmosphere.
– Depending on the operating conditions, an explosion may occur due
to air penetrating the hood chamber or due to an explosive gas mix-
ture with simultaneously existing ignition source.
This can result in injury to persons and damage to property.

CAUTION!
Automatic shut-down
Depending on the equipment configuration, when the machine is switched off

via the speed measuring device or inert gas blanketing monitoring facility (pres-
sure/flow) the machine can run down freely or braked by means of a frequency
NOTE converter.
8090-9001-100 / 0306
9.3.2 Opening the machine

When a machine has to be opened, the following points must be observed.
• Do not loosen any part before the machine has come to a standstill.
• The safety aspects below must be assured:
– The machine is at standstill.
– The nitrogen supply must be shut off.
– The electrical safety must be ensured.
Opening the machine can release large quantities of nitrogen or residues
of combustible gases or product residues.
Take in-plant precautionary measures!
Caution
9.4 Maintenance
• Carry out daily visual checks for leakage of lubricants or process liquids.
Eliminate leakages immediately to assure safe operation.
9.4.1 Maintaining the motor bearings
For lubrication or replacement of the motor bearings, refer to the instruc-

tions of the motor manufacturer (see motor plate) or in the instruction
Instruction manual manual supplied with the motor.
8090-9001-100 / 0306
Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
8090-9001-100 / 0306
10 Datasheet
10.1 Data sheet ...........................................................................................107
8090-9001-100 / 0306
Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
8090-9001-100 / 0306
10.1 Data sheet

This data sheet contains data important fort he safe operation and assembly of
the centrifugal mixer. It is only valid when no data sheet in accordance with
DIN/EN 12547 is enclosed with the complete set of documentation.
Subject to modification!
If a datasheet conforming to DIN/EN 12547 is enclosed with the complete
set of documentation, the datasheet in the instruction manual is null and
NOTE void.
Minimum lifting capacity of hoist for removing the mixer: Kg
Bowl speed: See mixer name-

plate
Starting time: 5 sec
Run-down time: 60 sec
Motor data: See motor name-

plate
Depending on the version, the pressure in the discharge min. 0,5 and max
line of the mixer must not exceed or drop below the follow- 10 bar
ing limit values:
Temperature monitoring
The temperature must not exceed the following value. max. 100 °C
8090-9001-100 / 0306
Take the Best – Separate the Rest
A company of GEA Group
Westfalia Separator AG ● Werner-Habig-Straße 1 ● D-59302 Oelde (Germany)

Tel.: +49 (0) 25 22 / 77-0 ● Fax: +49 (0) 25 22 / 77-24 88 ●
http://www.westfalia-separator.com/● mailto:[email protected]

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Westfalia Separator AG

1.1 About this manual .................................................................................... 8

2.1 Fundamental safety precautions ........................................................... 15

3 Machines in explosion-hazarded zones 53

3.1 Instructions for the operator................................................................... 54

4.1 Application ............................................................................................. 70

5.1 Installing the mixer in ATEX zone 1....................................................... 75

6.1 Three-phase AC motor .......................................................................... 78

7.1 Bowl parts .............................................................................................. 82

8.1 Important hints ....................................................................................... 84

9.1 Before every start-up ...........................................................................100

10.1 Data sheet ...........................................................................................107

1.1 About this manual .................................................................................... 8

1.1 About this manual

In the interest of your personal safety and a better understanding of the

The documentation contains important information for all persons who

1.2 For your safety

• Observe accident prevention regulations.

The local safety and accident prevention regulations apply uncondi-

• Refer to the documentation supplied.

Proceed only in accordance with the documentation supplied.

• Operate the centrifugal mixer only in accordance with agreed

• Maintain the centrifugal mixer.

as specified in the documentation supplied.

• Carry out safety checks on the centrifugal mixer,

as described in the documentation supplied.

• Liability for the function of the machine passes to the owner.

Liability for the function of the machine passes unconditionally to the

1.3 Note on the symbols used in the documentation

Below is an explanation of the meaning of the symbols used in the documenta-

This symbol indicates potential danger to persons.

Max. admissible rated bowl speed in min-1

Max. admissible density in kg/dm3 of product

Heavy liquid kg/dm3 Solids kg/dm3

min/max throughput m3/h

min./max. temperature of product in °C

min/max housing pressure range in bar

2.1 Fundamental safety precautions ........................................................... 15

2.7.3 Safety precautions for start-up .............................................................. 41

2.1 Fundamental safety precautions

Every person assigned the responsibility of installing, operating, maintaining and

2.1.1 Other elements on the machine

2.2 Symbols and abbreviations used

2.2.1 Concrete safety precautions and symbols used

• product and machine

This symbol indicates potential danger to persons.

This symbol indicates potential risks to machine, material and environ-

2.2.2 Further symbols for information

2.3 Correct usage

The centrifugal mixer is designed

In particular, only products may be used which conform to the specifications on

2.3.1 Incorrect usage

• Products not specified in the documentation or on a datasheet furnished with

• Constructional alterations may not be made to the centrifugal mixer, fittings

• Process parameters such as

– admissible flow rates

2.4 Safety markings on the machine

2.4.1 Current safety markings as from 2004

2.4.2 Meaning of the safety markings