Bauer Separator Compact Operating Manual

OPERATING MANUAL

for

Separator Compact

Version: I- 2014

II

Operating Manual for Bauer Separator Compact

S

Thank you for buying a BAUER separator!

This operating manual is an important document that describes the operation and maintenance of
the BAUER SEPARATOR.

All information contained in this manual is based on the latest product details available at the time of
printing. If you need still more information, please ask your dealer or contact the BAUER company
directly.

Please note that the content of this manual neither constitutes part of nor alters in any way any previ­ous or existing agreement, promise or legal relationship. BAUER’s obligations are based solely on
the respective purchase contract, which also contains the complete and only valid warranty agree­ment. Said contractual warranty is neither extended nor limited by the content of this manual.

The BAUER SEPARATOR is designed for safe and reliable operation provided it is operated in ac­cordance with this operating manual.
You should therefore study this manual thoroughly before starting your BAUER SEPARATOR! Strict-
ly observe all instructions pertaining to system handling, operation and service!

If these conditions are ensured, the BAUER SEPARATOR will operate to your complete satisfaction
for many years to come.

The content of this operating manual is the intellectual property of the company BAUER GesmbH
and/or its supplier companies. The available information may only be used in connection with the cre­ation of specification-compliant documents in the course of an order from the BAUER company.
Without express written permission from the BAUER company, no reproduction or sharing of this
operating manual is permitted, even in excerpts.
The BAUER company reserves the right to make changes at any time without notice and without as­suming any liability!

In the interests of a clearer presentation and due to the large number of possibilities, this operating
manual does not contain all detailed information and, in particular, cannot address every conceivable
operating and maintenance situation.

WARNING

Failure to follow this manual may cause personal injury or damage the

equipment!

NOTE

This manual is to be considered an integral part of the BAUER SEPARATOR. Sup-
pliers of both new and used systems are advised to put down in writing that they
delivered the manual together with the system.

Please make this manual available to your staff. State the pump type and serial number of your
BAUER SEPARATOR in all inquiries, correspondence, warranty problems or parts orders. You will
find this information on the type plate riveted onto the screen housing of the separator.

We wish you great success with your BAUER SEPARATOR!

Operating Manual for Bauer Separator Compact

1

PRODUCT DETAILS

Type designation:

Separator Compact

Serial number1:

Dealer:

Name:

Address:

Tel. / fax:

Shipping date:

Producer of the machine:

Röhren- und Pumpenwerk BAUER Ges.m.b.H.

Kowaldstr. 2

A - 8570 Voitsberg

Tel.: [phone] - 0

Fax: [phone] /-340

e-mail: [e-mail]
www.bauer-at.com

Owner or operator:

Name:

Address:

Tel. / Fax:

Note: Make a note of the type designation and serial number of your separator and its accessories.
Include these numbers along with all contact with your dealer.

1

It is very important to include with all guarantee claims and all correspondence related with this ma­chine the entire serial number group, including all letters, both for the machine and for its relevant
components. This point cannot be stressed enough.

2

Operating Manual for Bauer Separator Compact

S

TABLE OF CONTENTS

1 GENERAL SAFETY INSTRUCTIONS ............................................................................................................... 4

1.1 Warnings and Symbols ................................................................................................................................ 4

1.2 Duty to Furnish Information ......................................................................................................................... 4

1.3 Product Liability............................................................................................................................................ 4

1.4 Qualified Operators ..................................................................................................................................... 5

1.5 Intended Use ............................................................................................................................................... 5

1.6 Unauthorized Modification and Manufacture of Replacement Parts ........................................................... 5

1.7 Disposal ....................................................................................................................................................... 5

2 GENERAL INSTRUCTIONS FOR SAFETY AND ACCIDENT PREVENTION .................................................. 6

3 FUNCTION DESCRIPTION ................................................................................................................................ 9

4 SETUP OF THE SEPARATOR ........................................................................................................................ 10

4.1 Installation Diagram ................................................................................................................................... 10

4.2 Condition of the BAUER Separator upon Delivery .................................................................................... 10

4.3 Required Tools .......................................................................................................................................... 10

4.4 Features, Identification and Information .................................................................................................... 11

4.5 Type plates - Information Signs ................................................................................................................. 12

4.5.1 Information on the Separator Type Plate ........................................................................................... 12

4.5.2 Information Signs................................................................................................................................ 12

4.6 Separator Technical Data .......................................................................................................................... 12

4.7 Setup and Assembly .................................................................................................................................. 13

4.8 Complete System ...................................................................................................................................... 14

4.8.1 Inflow Setup ........................................................................................................................................ 15

4.8.2 Drainage Line ..................................................................................................................................... 15

5 ELECTRICAL CONNECTION .......................................................................................................................... 16

5.1 Setup and Operation of the Motor ............................................................................................................. 17

5.2 Condensate Hole ....................................................................................................................................... 17

5.3 Installation Without Switch Cabinet ........................................................................................................... 17

6 PREPARATION FOR INITIAL STARTUP ........................................................................................................ 18

7 INITIAL STARTUP ........................................................................................................................................... 18

7.1 Configuration Instructions .......................................................................................................................... 18

7.2 Solid Cake Formation ................................................................................................................................ 19

7.3 Configuration to Stabilize the Solid Cake .................................................................................................. 20

7.3.1 Cake Too Firm .................................................................................................................................... 20

7.3.2 Cake Too Soft .................................................................................................................................... 20

7.4 Additional Instructions for Flawless Operation .......................................................................................... 21

8 WINTER OPERATION ..................................................................................................................................... 21

9 TEST FOR SEPARATION CAPABILITY ......................................................................................................... 22

10 LIQUID CLEANING .......................................................................................................................................... 23

11 IMPORTANT ASPECTS TO BE CONSIDERED DURING OPERATION ........................................................ 23

12 TAKING THE SEPARATOR OUT OF OPERATION ....................................................................................... 23

Operating Manual for Bauer Separator Compact

3

13 MAINTENANCE AND INSPECTION ................................................................................................................ 24

13.1 Gearbox and Motor ................................................................................................................................ 24

13.1.1 Supply with Sealing Medium ............................................................................................................... 24

13.2 Inspection of the Sieve and the Guide Rails .......................................................................................... 25

13.3 Inspecting and Reinstalling the Sieve .................................................................................................... 27

13.4 Inspecting and Reinstalling the Screw ................................................................................................... 28

13.5 Evaluation Criteria for the Screw and Sieve with Regard to Wear and Refurbishing ............................ 29

13.6 Summary of Maintenance and Inspection Intervals ............................................................................... 30

14 PROBLEMS - TROUBLESHOOTING.............................................................................................................. 31

14.1 Principles of a “Normal” Operating Condition ........................................................................................ 31

14.2 Troubleshooting ..................................................................................................................................... 32

15 ACCESSORIES ................................................................................................................................................ 35

15.1 Separator Control ................................................................................................................................... 35

15.1.1 Motor protection circuit breaker F1 ..................................................................................................... 35

16 NOTES .............................................................................................................................................................. 36

17 CONFORMITY DECLARATION ....................................................................................................................... 37

4

Operating Manual for Bauer Separator Compact

S

1 GENERAL SAFETY INSTRUCTIONS

This operating manual contains important information that must be observed during setup, operation
and maintenance. For this reason, it must always be read and observed very carefully by the installa­tion technician as well as the qualified personnel. It must always be available at the usage location of
the machine.

If the installation and maintenance are not carried out according to the operating manual, all warranty
claims due to faults become void.

The customer is responsible for the proper setup of all equipment. Read the instructions before as­sembling or installing the machine. Promised performance characteristics of the machine and the add­on components as well as the fulfillment of any warranty claims are dependent on compliance with
these instructions.

The CE mark applied by the manufacturer provides external verification of the ma­chine’s conformity with the provisions of the Machinery Directive and with other
pertinent EC directives.

1.1 WARNINGS AND SYMBOLS

The following notes and warnings are used in this operating manual for especially important instruc­tions:

DANGER

Information, requirements or prohibitions to protect against serious injury or

property damage.

WARNING

Special information on preventing minor injuries or requirements and prohibi-

tions to prevent damage to the machine.

NOTE

Special instructions to simplify working with the machine or to aid in efficient use

of the machine.

To prevent malfunctions that could directly or indirectly result in serious injuries or property
damage, it is equally important to comply with any other instructions concerning transport,
assembly, operation and maintenance as well as reference data (in the operating manual, the
product documentation or on the equipment itself).

1.2 DUTY TO FURNISH INFORMATION

When passing the machine on to a new owner, the customer is obliged also to hand over the operating
manual to the new owner. The recipient of the machine must be instructed with reference to the men­tioned regulations.

Should you encounter difficulties in understanding this manual or other instructions, contact the re­spective dealer or the BAUER company for

any necessary clarifications.

1.3 PRODUCT LIABILITY

According to the Product Liability Act, every farmer is an entrepreneur!
In accordance with Section 9 PHG (Product Liability Act), liability for damage to physical property
caused by defective products is expressly excluded. This exclusion of liability also applies to parts not
manufactured by BAUER itself but purchased from external suppliers.

Operating Manual for Bauer Separator Compact

5

1.4 QUALIFIED OPERATORS

These are persons who on behalf of their training, experience and instruction as well as their
knowledge of relevant standards, rules, precautions to be taken for accident prevention and prevailing
operating conditions have been authorized by the person in charge of system safety to perform the
respective tasks required and in doing so are able to recognize and avoid potential hazards. The statu­tory minimum age for the operating and maintenance personnel must be observed. Among other
things, knowledge of first aid procedures is also required.

1.5 INTENDED USE

 The BAUER separator is designed exclusively for solid-liquid separation in agricultural applications

(intended use).

 Any use of the machine beyond this intended use is considered non-conforming. The manufactur-

er is not liable for damage resulting from such non-conforming use, the sole liability for damage
from non-conforming use lies with the user.

 Intended use also includes compliance with manufacturer’s operating, maintenance and service

instructions.

 The BAUER separator may be used and operated only by persons who are familiar with the sys-

tem and aware of the hazards involved.

 All relevant rules for accident prevention as well as any other generally accepted rules and regula-

tions relating to safety, occupational medicine and traffic laws must be strictly observed.

 Unauthorized modifications to the machine release the manufacturer from liability for damage re-

sulting from such modifications.

1.6 UNAUTHORIZED MODIFICATION AND MANUFACTURE OF REPLACEMENT PARTS

Modifications or alterations to the machine are only permitted after consultation with the manufacturer.
Original replacement parts and authorized accessories from the manufacturer serve the interests of
safety. The use of other parts voids the manufacturer’s liability for any resulting consequences.

The replacement parts used must correspond to the technical requirements established by the manu­facturer of the system. The replacement and wearing parts delivered with the machine or via subse­quent orders satisfy this condition.

1.7 DISPOSAL

The machine must be disposed of according to the local disposal regulations.
The user must ensure safe and environmentally friendly disposal of operating materials and ancillary
materials as well as replaced parts. Dispose of oil, grease, and filters in accordance with regulations!

6

Operating Manual for Bauer Separator Compact

S

2 GENERAL INSTRUCTIONS FOR SAFETY AND ACCIDENT PREVEN-

TION

Check the operational safety of the machine before every start !

 All regulations of public authorities that apply to the operation and maintenance of the system must be strict-

ly observed.

 In addition to the operating manual, all generally applicable statutory and otherwise mandatory regulations

on accident prevention and environmental protection must be separately prescribed and observed.
Such obligations may concern, for instance, the handling of hazardous substances, the provision and wear-

ing of personal protective gear or traffic and road safety regulations.

 The operating manual should be extended with the instructions for taking into account special operating

conditions, such as with regard to the work organization, work processes and the active personnel. The su­pervisory and reporting obligations of the operator must also be clearly regulated.

 To ensure your safety and the safety of your employees, every person who is responsible for operating the

system must also be familiar with these obligations. It is too late for this when the system is already running!

 The personnel assigned to operating the plant must have read the operating manual and in particular the

section “General Instructions for Safety and Accident Prevention" before starting work.

 Every person must be aware of the safety measures that must be complied with during work on electro-

mechanical components and machines.

 Only trained personnel may enter the hazard zone of the machine.
 Only trained personnel may be assigned to work with the machine. The respective competencies of the

personnel for the operation, setup, maintaining and repair of the machine must be clearly defined. It must
also be ensured that only appropriately authorized personnel work on the system.

 Personnel who are being trained, taught, instructed or are participating in a general training program may

only work on the system under the constant supervision of a person experienced in operation of the system.

 The safety- and risk-conscious work by the personnel in compliance with the operating manual must be

checked at least at certain intervals.

 The personnel assigned to operate the machine may not have:

 Exposed long hair
 Loose clothing
 Jewelry, including rings and drop earrings

Such items could get stuck and/or drawn into the machine, resulting in possible injuries.

 The operating personnel of the system must be familiarized with the fire alarm and fire-fighting options.
 The wearing of personal protective gear such as hearing protection, safety glasses, safety shoes, etc. dur-

ing operation of the system must be required by means of rules or regulations.

 All safety information and warnings present on the machine must be pointed out, and these must be kept on

the system in a clearly visible and legible condition.

 In event of safety-relevant changes to the system or its operating behavior, the system must be immediately

shut down and the fault must be reported to the competent person or office.

 Replace pipelines and hoses in the specified or otherwise reasonable intervals, even if no operationally rel-

evant defect is discernible.

 Intervals that are required or specified in the operating manual for regular daily, weekly and monthly inspec-

tions and tests must be complied with. Appropriate tools and equipment must be kept available for the per­formance of such work.

 Any potentially unsafe work on the machine must be avoided. The system may only be used in accordance

with its intended use. All necessary measures must be taken to ensure that the system is only operated in a
safe and fully functional condition.

 The system may only be started up if all protective and safety-related features are fully functional. This in-

cludes the fact that all removable protective features, EMERGENCY STOP buttons and covers must be
present and functional.

WARNING

Operating Manual for Bauer Separator Compact

7

 The system must be inspected for externally identifiable defects before it is started up each time. Any

changes that occur, including changes to the operating behavior and functional disruptions, must be imme­diately reported to the competent party. The system must be immediately shut down and secured.

 Procedures for switching the machine on and off as well as inspection of the control indicators must be car-

ried out as described in the operating manual.

 Before switching on or starting up the machine, it must be ensured that no one will be endangered by the

starting up of the machine.

 The correct functioning of the controller must be checked before the start of work. Before startup, all tools

and assembly aids must be stored safely to prevent accidents.

 The maintenance, configuration and inspection activities and deadlines specified in the operating manual

must be complied with. The specified deadlines are maximum deadlines and may not be exceeded. Such
work as well as the replacement of components may only be performed by qualified personnel.

 During transport of the separator, measures must be taken to ensure sufficient securing of the transport ar-

ea.

 The required switch-on and switch-off procedures according to the operating manual and the instructions

for maintenance work must be observed during all work involving the operation, production adaptation, con­version or configuration of the system and its safety-related features as well as all work involving inspection,
maintenance and repair.

 The operating personnel must be informed of special work, repair work or conversion work in a timely fash-

ion prior to starting the work. A supervisor must always be appointed during the performance of such work.

 The work area must be blocked off and secured by a wide margin during such work, if necessary. Unau-

thorized persons must be prevented from entering.

 As a rule, maintenance and cleaning work as well as repairs of malfunctions may take place only with the

drive switched off and the motor at rest (switch off and lock the main switch or disconnect the supply of
electricity).

 Watch out for the unexpected starting of the system.
 It must be noted that a pressed EMERGENCY OFF button does not provide any protection against unau-

thorized starting of the machine.

 During disassembly and assembly, large individual parts and entire assemblies must be carefully fastened

and secured to lifting equipment. Only suitable lifting equipment and load handling devices with sufficient
carrying capacity and no technical operating defects may be used. Standing or working under suspended
loads is not permitted. Grips, steps, railings, landings, platforms and ladders must be cleaned of oil, dirt,
snow and ice before all activity on the system.

 If the BAUER separator is installed on an elevated platform, this must be equipped with a railing. The plat-

form should be sufficiently dimensioned to allow maintenance and service work.

 Any openings in the platform must be sufficiently secured against tripping or falling through.
 Access stairs must be equipped with hand rails in accordance with applicable regulations.
 If access stairs cannot be used due to tight space conditions, permanently mounted ladders with back pro-

tection must be used.

 Securing of personnel with suitable supporting elements is required during all maintenance work on an ele-

vated system.

 During assembly work above head height, climbing aids and work platforms intended for such work or spe-

cially adapted for purposes of safety must be used. Never use system components as climbing aids. The
system and, in particular, connections and bolt connections must be cleaned of oil, grease or care agents
prior to the start of maintenance or repair work. No aggressive cleaning agents may be used. Only fiber-free
cleaning cloths may be used.

 Before cleaning the system with water, steam, high-pressure cleaners or other cleaning aids, cover / tape

over all openings into which no water, steam or cleaning agents may enter for safety and/or functional rea­sons. Electric motors and electronic switch cabinets are at particular risk. After cleaning, the applied covers
/ tape must be completely removed again.

 Wear appropriate protective gear to protect against flying particles while cleaning with compressed air or

steam jets.

 After cleaning, all gear oil and media lines as well as all electrical connections must be inspected for leaks,

loosened connections, abrasions and damage. Identified defects must be corrected immediately.

8

Operating Manual for Bauer Separator Compact

S

 The bolt connections loosened during maintenance and repair work must be tightened again. Observe the

required tightening torques.

 If it is necessary to remove safety features during maintenance, setup or repairing, the safety equipment

must be re-installed and inspected immediately after completion of the work.

 Do not start the machine unless all guards and safety devices are mounted completely and in proper work-

ing position!

 Protective caps and covers may not be removed.
 The stickers affixed to the device with safety and warning signs provide important instructions for safe op-

eration; following these instructions is intended to keep you safe! These may not be removed.

 Check the proper seat of nuts and bolts regularly, and tighten them, if needed!
 When replacing operating elements with blades, use a suitable tool and wear gloves.

 The system is electrically operated. Take special care when performing work in the area of electrically op-

erated system components.

 Work on electrical and electronic components of the system may only be performed by a trained electrician

or otherwise appropriately trained personnel under the guidance and supervision of a trained electrician in
accordance with the applicable electrical and electronic regulations.

 With regard to an ATEX 95 zone 22 certification, see the special remarks.
 Never touch rotating or moving parts of the machines with hands or feet.
 Never reach with hands, tools or other parts over the inflow or hopper in the area of the auger while the ma-

chine is running.

 In handling slurry, always remember that the gases produced by the slurry are highly toxic and explosive in

combination with oxygen. Open flame, light checks, spark creation and smoking are therefore prohibited!

 When using the retention or alternating retention method, special care must be taken in the area of the

opened sliding gates to the pre-pool before the main tank or to cross channels due to the formation of gas­es. In addition, special care is required at stirring and withdrawal points while the stirring machines or
pumps are active!

 Keep the machine clean to decrease the risk of fire!
 Always ensure sufficient ventilation when working with slurry!
 When working with biologically active materials in connection with the BAUER separator or connected com-

ponents, the decomposition of these materials can lead to the production of life-threatening gases, espe­cially in enclosed spaces. Always ensure sufficient supply and exhaust ventilation and/or appropriate protec­tive clothing before entering such areas.

DANGER

In addition to the mechanical dangers of moving parts or parts under pressure, the opera­tion of slurry handling machines also poses risks in connection with gases produced by
liquid manure. These gases (carbon dioxide CO2, ammonia NH3, hydrogen sulfide H2S, me­thane CH4) can result in poisoning as well as explosions.

Especially when operating mixers, stirring machines, recirculation systems, pipe nozzles
and slurry aeration systems, care must be taken that no gases can flow into the stall from
exterior tanks or containers (install siphons or sliders).

Sufficient forced ventilation of the stall area must be ensured while handling slurry in the
stall area.

Operating Manual for Bauer Separator Compact

9

3 FUNCTION DESCRIPTION

The BAUER separator serves for separating pumpable slurry (solid-liquid mixtures with relatively low
solid matter content and no foreign bodies such as metal parts, stones, wood or rags) into solid and
liquid (thin slurry) fractions. As a compact device, it combines the functions of two separators, specifi­cally the functions of a screen and a press.

The BAUER separator is designed for sustained operation outdoors. It operates unimpaired in a tem-

perature range of 0-40 °C; in event of freezing temperatures, it must be ensured that the separator is
cleaned completely each time before being taken out of operation. Conditions of high humidity (e.g.
locations near to the coast) and extreme sunlight require special designs for the gears and motors.
Consult the manufacturer concerning such designs.
When selecting the feed pump and the overflow line, make certain that the separator is operated under
no pressure.

In the inflow area, the mixture is drained of water via gravity inside the screen. The interior auger
transports the pre-drained material horizontally toward the solid outlet. Along the last section of the
transport path, the auger presses out additional liquid, which escapes the separator through the screen
as thin slurry. The required contact pressure is applied to the escaping solid by a system consisting of
a cap loaded by a weighted lever.

The solid-liquid separation depends entirely on the type of slurry. For example, the extent to which wa­ter can be drained differs greatly between dairy cattle, beef cattle and pig slurry. Users of the BAUER
separator have many options for optimizing the separating result.

 The throughput can be increased be selecting a larger screen gap width.
 The residual moisture in the separated solid decreases as the contact pressure of the output

regulator is increased.

 The solid matter content in the separated liquid can be reduced with a smaller screen gap width.
 The degree of solid separation is improved by smaller screen gap widths.

More information about the configuration options can be found in section 7 “Initial Startup”.

Fig. 3-1 Function description

Raw liquid manure

Transport and pressing screw (19 rpm)

Sieve element

Solid phase

Liquid phase

10

Operating Manual for Bauer Separator Compact

S

Ventilation

4 SETUP OF THE SEPARATOR

4.1 INSTALLATION DIAGRAM

4.2 CONDITION OF THE BAUER SEPARATOR UPON DELIVERY

The BAUER separator was developed by the company BAUER GesmbH. The separator is delivered as
a unit, including installed electric motor, on a pallet. The inflow element with outlet for overflow and
ventilation as well as the outlet bend are enclosed separately for easier transport and must be installed
before the initial startup.

You must connect the geared motor of the separator to the power supply of the optionally available
switch cabinet and connect this to the electricity supply. It is recommended that the corresponding
electrical control for the separator or for the separator and the Bauer submersed motor pump be pur­chased from BAUER since it will be already adapted to the corresponding drive motors.

Connecting the supplied hoses, if included, to the inflow and discharge connections of the machine
completes the installation of the BAUER separator.

DANGER

Work on electrical and electronic components of the system may only be per­formed by a trained electrician or otherwise appropriately trained personnel under
the guidance and supervision of a trained electrician in accordance with the ap­plicable electrical and electronic regulations.

4.3 REQUIRED TOOLS

Special tools are not required for setting up the separator.
Standard tools for assembly and electrical tools are required for assembly, setup and disassembly.

The customer must check based on the dimensions and weight of the separator whether the available
lifting equipment (forklift, tractor with front loader, crane with corresponding belts or chains) is sufficient
for setting up the separator.

Distribution of the
solid phase

Sale of the solid
phase

Composting of
the solid phase

BAUER
Separator
Compact

BAUER MAGNUM
pump system

Distribution of the
liquid phase
via BAUER
slurry injector
Cerres

Distribution of the
liquid phase
via BAUER
Pivot or Rainstar

BAUER
submersed
motor pump
MAGNUM S

BAUER
slurry mixer

BAUER
submersed
motor stirrer
TMRW

BAUER eccentric
spiral pump Helix

Liquid
phase

Solid
phase

Inflow

Overflow

BIOGAS PLANT

Fig. 4-1 Installation diagram