Heating loop filtration with magnetic and centrifugal extraction and
integrated aeration unit
Valid for: EU countries and Switzerland
Language: English
Attention:
Carefully read through the installation and operating instructions
and safety information before
installing and putting the unit into
service.
These instructions must always
be issued to the owner/user.
Dear customer,
thank you for the confidence you have
shown in us by purchasing this unit. With
this magnetite filter you have purchased
a state of the art unit.
This multi-functional unit is designed for
use in heating loop systems and features
a centrifugal particle removal system, a
magnetic removal unit and an integrated
aeration feature.
The unit removes physical impurities in
the loop (e.g. rusty sludge) which can
lead to malfunctions in the control and
regulation mechanisms in the system
and the high-grade magnet traps the
sludge (magnetite) within the unit.
The integrated aeration unit allows for
the removal of corrosive gases in solution (eg. Hydrogen and oxygen)
Each unit is thoroughly checked before
delivery. Should difficulties occur,
please contact the responsible customer
service (see back page).
Trademarks:
Trademarks used in this document are protected
and registered trademarks of the respective
holder.
11. Customer service ............................ 24
1.About this instruction
manual
(see chapter “Safety information and
dangers due to non-compliance”)
The instruction manual must be permanently
available at the place in which the magnetite
filter is used.
This instruction manual is intended to make
it easier to familiarize yourself with the magnetite filter and its possible intended uses.
The instruction manual contains important
information in order to safely, properly and
economically run the magnetite filter.
It contains fundamental information, which
must be observed during installation, operation and maintenance. Observance of this
information helps to avoid dangers, reduce
repair costs and increase the reliability and
service life of the magnetite filter.
The instruction manual must be read and
used by each person entrusted with carrying
out work on the magnetite filter, for example:
–Installation
–Operation
– Maintenance
(servicing, inspection, repair)
Installation and maintenance may only be
carried out by personnel authorized by the
manufacturer, who are capable of fulfilling
the instructions given in the installation and
operating instructions and the countryspecific regulations.
Apart from the instruction manual and the legally binding accident prevention provisions
applicable in the country and place of use,
the recognized technical regulations for safe
and proper work must also be observed.
Therefore, this instruction manual must
always be read by the fitter and responsible
skilled personnel/owner or operator before
JUDO MAFI3
About this instruction manual
ATTE NTION
installation, commissioning and maintenance.
Not only the general safety notes given in
the chapter “Intended use” are to be observed, but also the special safety notes
inserted under the other main items.
1.1Symbols used
Notes directly attached to the magnetite filter, e.g.
– Hot surface do not touch
– Labelling
– Cleaning instructions
must always be observed and kept in a fully
legible condition.
The safety notes contained in this instruction
manual are labelled with the following
symbols:
Notes on existing
dangers
Warning, electrical voltage
Hot surface
Torques specified by the
manufacturer
Do not use if you wear a pace
maker!
1.2
Safety information and dangers
due to non-compliance
In detail, failure to observe the general danger symbols can result, for example, in the
following risks:
– Failure of important functions of the
magnetite filter.
– Danger to persons due to electrical and
mechanical effects.
– Danger to persons and the environment
due to hot water leakage. Danger of
scalding!
Refrain from any unsafe working methods.
Failure to comply with this instruction manu-
al and the safety information can not only result in dangers for people but can also harm
the environment and the unit.
1.3Units used
In derogation of the International System of
Units SI (Système International d’Unités),
the following units are used:
UnitsConversion
bar
1" DN 25
4JUDO MAFI
1 bar = 10
5
Pa = 0.1 N/mm²
Intended use
2.Intended use
Installation and use of the magnetite filter
are each subject to the applicable national
regulations.
In addition to the operating instructions and
the obliging regulations concerning accident
prevention that exist in the country of operation and the location of use, the established
technical regulations concerning safe and
professional work, should also be observed.
The magnetite filter is produced to state of
the art standards and the generally
accepted safety regulations in Germany.
The magnetite filter may only be used as described in the instruction manual. Any other
or further use is deemed not to be intended
use.
Additional dangers exist in case of non-intended use and failure to observe the danger symbols and safety information. The
manufacturer/supplier are not liable for any
losses or damage resulting from this. The
risk is solely borne by the user.
Intended use also includes observing the instruction manual.
The manufacturer/supplier must always be
consulted before using the magnetite filter
outside the use limitations given in the instruction manual.
The magnetite filter is only to be used in a
technically perfect condition, for its intended
use, safely and aware of the dangers and
with full observance of the instruction manual!
Have any malfunctions corrected immediately!
2.1Water pressure
Water pressure should not sink below 1 bar
as this will affect the efficiency when flushing
sludge out of the unit! Pressure within the
system should be checked after flushing as
a top up may be required.
2.2Notes on special dangers
2.2.1 Electrical devices/equipment
There must not be any electrical cables and devices underneath or in
the immediate vicinity of the magnet-ite filter!
Electrical devices/equipment that are not
splash-water proof and are situated in the direct vicinity of the magnetite filter may be
damaged by water leaking from the magnetite filter when flushing or by non-correct usage. In addition this may also result short circuits if these electrical devices/equipment
being connected to the electrical power supply. In the event of such cases persons are
at risk and may sustain electrical shocks.
Therefore any electrical devices/equipment
situated in the direct vicinity should be
splash-water proof, respectively comply with
the statutory requirements for wet areas
(IP44).
JUDO MAFI5
3.Product information
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Product information
4.1.1 Requirements for the place of
installation
3.1Intended purpose
This magnetite filter is for use in heating
loops up to a max. heating water temperature of 90 °C and a max. operating pressure
of 6 bar.
Do not install in drinking water systems!
4.Installation
4.1General
(see chapter “Safety information and
dangers due to non-compliance”)
The unit may only be installed by skilled personnel.
The chapter “Intended use” must always be
observed!
The pipes must be able to safely support the
magnetite filter.
Otherwise mechanical damage or fractures/
bursts can occur in the pipes. This can result
in major water damage. People close to the
magnetite filter are exposed to a health risk
due to hot water released. Therefore, if necessary, the pipes must be additionally fixed
or supported.
For convenient operation and maintenance
it is absolutely necessary to ensure the given spacings (see chapter “Installation dimensions”). A space of at least 250 mm
should be maintained above and below the
magnetite filter. These distances are necessary to obtain an efficient rinse (see chapter
“Rinsing”).
The room where the unit is installed must
be dry and frost free! Unauthorised persons must not have access to the magnetite filter!
(see chapter “Safety information and
dangers due to non-compliance”)
– This magnetite filter is designed for use
in heating loop systems and can be in-
stalled in both the supply and return sec-
tions of the loop. Where no maintenance
during heating operation is possible, a
bypass should also be installed.
– In order to be able to safely discharge
the wastewater (rinsing) in operation and
in case of any defects that occur in the
system, precise compliance with the de-
tails given in the
necessary!
If the wastewater (backwashing) cannot
be safely and completely discharged,
the house and installations can be dam-
aged by water.
– A shut-off valve must be installed up-
stream and downstream of the magnet-
ite filter! This enables the water supply to
the magnetite filter to be interrupted dur-
ing installation, servicing/maintenance,
repairs and in case of malfunctions.
Floods and serious water damage to
house installations can therefore be
avoided.
– Consult your sales agent regarding suit-
ability of this unit for use with heating wa-
ter conditioning agents used by you.
“Installation”
chapter is
6JUDO MAFI
Installation
ATTE NTION
Heating feedHeating return
Boiler
Circulation pump
Fill and drain valve
1
2
3
4
5
Expansion vessel
Water supply Shut-off valve
Shut-off valve
Shut-off valve
4.2Installation position
(see chapter “Safety information and
dangers due to non-compliance”)
Always install the magnetite filter in a vertical position (± 5°)! Tensions which may
4.3Installation schematics
arise, eg. due to temperature fluctuations,
may eventually require the installation of
suitable expansion joints. Avoid changing
loads like pressure surges and high levels of
vibration.
The aeration unit must point upwards. This
is the only way to guarantee a proper functioning.
Fig. 1:Schematic JUDO MAFI with mobile heating water conditioning according to VDI 2035
1 JUDO HEIFI-FÜL PLUS
Heating resupply station with integrated pipe disconnector, type BA (order no.: 8060080)
Adaptor for dosing with QUICK-DOS (order no.: 8838188)
4 JUDO QUICK-DOS L / JUDO QUICK-DOS R / JUDO QUICK-DOS PLUS /
JUDO QUICK-DOS MINUS
Cleaning and protection agents for heating circuits (order no.: 8838185 / 8838186 /
8650015 / 8650016)
5 JUDO HEIFI PURE filling block 7500
Fill water demineralisation unit (order no.: 8068013)
or
JUDO HEIFI SOFT filling block 12000
Fill water softening unit (order no.: 8068012)
6 JUDO PURE 7500 Full demineralisation cartridge (order no.: 8068019),
or alternatively the floor-standing version JUDO PURE 25000 Full demineralisation
cartridge (order no.: 8068531) with adaptor kit (order no.: 8068532)
JUDO SOFT 12000 Softening cartridge (order no.: 8068018),
or alternatively the floor-standing version JUDO SOFT 60000 Softening cartridge
(order no.: 8068530) with adaptor kit (order no.: 8068532)
8JUDO MAFI
Installation
ATTE NTION
Profiled flange gasket
I
II
4.4Mounting the built-in rotary
flange
Install using the supplied built-in rotary
flange. The built-in rotary flange is used as a
connecting element with the heating circuit.
It is suitable for both horizontal and vertical
pipes.
The built-in rotary flange must be installed in the direction of flow. This is
marked by a cast in arrow (see fig. 3).
4.5Mounting the magnetite filter
The built-in rotary flange for the magnetite
filter is supplied with bayonet drill holes. The
necessary seals and screws for this magnetite filter have already been mounted.
Fig. 3:Built-in rotary flange
Failure to comply with this means that the
magnetite filter cannot work.
(see chapter “Safety information and
dangers due to non-compliance”)
The flange surface of the built-in rotary
flange must be in a vertical position! The
built-in rotary flange must be fitted so that
mechanical stresses cannot occur! Otherwise mechanical damage can result, the
pipe may burst or the built-in rotary flange
can break. This can result in major water
damage.
In this case, people close to the magnetite
filter are exposed to a health risk due to the
large quantities of water.
Therefore, during installation, ensure that no
large forces act on the pipe, built-in rotary
flange and magnetite filter.
Fig. 4:Built-in rotary flange
with bayonet fixture
Do not unscrew the screws!
– Insert the four flange screws in the bay-
onet drill holes on the built-in rotary
flange (see fig. 4 I).
– Turn the magnetite filter in a clockwise
direction as far as it will go (see fig. 4 II).
– Tighten the four flange screws.
Select the torque (approx. 4 Nm) so
that the gasket closes and the mag-netite filter is not damaged or
strained!
The section of the profiled flange gasket
must point towards the built-in rotary flange
(see fig. 3). Failure to observe this can lead
to leaks and water escaping. This can in turn
cause water damage to the house and its installations.
JUDO MAFI9
4.6Discharging the rinse water
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Installation
4.7Dangers during rinsing
(see chapter “Safety information and
dangers due to non-compliance”)
For the rinse water a wastewater connection
(for example a floor drainage) in accordance
with DIN 1986 must be in place. If there is no
wastewater connection an appropriately
sized bucket can be used.
(see chapter “Safety information and
dangers due to non-compliance”)
During the rinsing operation, hot water
comes out of the outlet nozzle.
Carry out with care, danger of scalding!
The following points must be noted if a bucket is used for rinsing:
– If the pressure is high, water can splash
out of the bucket, and the end of the
hose can pop out from the bucket.
Danger of scalding!
– In this case, damage to property close to
the magnetite filter is possible.
– The bucket must be adequately dimen-
sioned.
Danger, hot surface!
10JUDO MAFI
Operation
ATTE NTION
4
1
2
3
5.Operation
(see chapter “Safety information and
dangers due to non-compliance”)
Always observe the chapter “Intended use”!
5.1Commissioning
Before starting up (initial putting into service
or startup after maintenance work), fill the
magnetite filter with water! Observe the
following:
– Close or keep closed the shut-off valve
downstream of the unit to ensure that air
cannot be introduced into the system.
– Open the shut-off valve upstream of the
unit.
– The magnetite filter is now under operat-
ing pressure.
–
Air trapped within the unit is now automatically removed via the integrated
aeration unit. We recommend a rinse
after aeration (
– The filter comes delivered with the cover
cap (1) on the aeration unit (2) being
open one turn to ensure air can be evacuated freely (see fig. 5).
– The magnetite filter is ready for opera-
tion once the rinsing and aeration cycle
has been completed and the shut-off
valve downstream of the unit has been
opened.
see chapter “Rinsing”).
5.2Functional description
Centrifugal separator
Heating water flows through the built-in
rotary flange into the magnetite filter where
particles in the incoming water are set in
rotation by the splitter (3) and, as in a centrifugal unit, carried to the unit's outer wall
where they sink to the unit floor. Here they
are collected and flushed out through the
ball valve (4) (see chapters “Rinsing” and
“Rinse interval”). Gases present in the water
gather in the upper chamber of the unit and
are released out through the integrated
aeration system.
Fig. 5:Centrifugal separator
1 Cover cap
2 Aeration unit
3 Splitter
4 Ball valve
JUDO MAFI11
Operation
1
2
1 High performance magnets
2 Magnetic sludge
Magnetic separator
Magnetite sludge (Fe
) present in a
3O4
closed loop heating or cooling system can
result in malfunction of individual systems
components, massive loss of operating efficiency and, worst case, systems failure.
With its three high efficiency magnets (1) the
magnetite filter ensures that magnetic
sludge (2) is trapped and then physically removed from the system by regular rinsing
(see fig. 6).
Before rinsing, close the shut-off valve
downstream of the magnetite filter, then pull
the magnet holder on the front of the unit towards you to allow the sludge collected
there to drop to the unit floor (see chapter
“Cleaning the magnetic separator”). A rinse
may then be carried out (see chapters “Rinsing” and “Rinse interval”). The magnetite filter operates in a constant flow rate and
causes only a small pressure loss.
High levels of oxygen concentration can also be found in closed loop systems. Weak
points within the system (e.g. non diffusion
resistant plastic pipes or membranes) mean
can enter the system on an ongoing
that O
2
basis. In combination with water, this results
in surface corrosion successively removing
material. The rate of this corrosion progress
is mainly determined by the factors O
con-
2
tent and time. Systems containing sludge so
formed are not only more liable to malfunction, but also operate at much lower efficiency levels. The water quality within such systems is often unstable and, especially where
movement is less volatile, at the upper limits
of requirements. A result of this may be corrosion (pitting) and resulting leakage.
Sludge deposits greatly affect the rate of
heat transfer. Although the performance data is constantly dropping, the actual cause of
the problem is often not recognised until it is
too late.
Fig. 6:Magnetic separator in operation
12JUDO MAFI
5.3Cleaning the magnetic
10 s
1.2.3.
separator
Operation
The magnetic separator is used to retain
magnetic sludge in the unit, and this is then
permanently removed from the system by
regular rinsing (see chapter “Rinsing”).
The shut-off valve downstream of the filter
must be closed before rinsing.
The black magnet holder in the front of the
unit is then pulled fully open to allow the
sludge retained to drop tot he unit floor (see
fig. 7).
The draw may be closed again after approx.
10 seconds and the unit rinsed (see chapter
“Rinsing”).
Fig. 7:Cleaning the magnetic separator
Failure to close the shut-off valve
downstream of the filter before cleaning will result in sludge being returned
to the heating loop.
JUDO MAFI13
5.4Rinsing
ATTE NTION
1
3
2
open!
Operation
5.5Rinse interval
In order to remove sludge and particles from
the system, the magnetite filter must be
rinsed at regular intervals.
Refer to chapter “Dangers during rinsing”
before commencing!
In order to obtain an optimal unit rinse, first
close the shut-off valve downstream of the
filter. To rinse open the ball valve at the bottom of the unit. Observe the following:
The filter comes delivered with the ball valve
closed and capped. Before opening the ball
valve, remove the cap (1), then insert the
spout (2) and fix it in place with the union nut
(3). The ball valve may now be opened by
means of the cap (see fig. 8).
Fig. 8:Safety ball valve
Danger of scalding!
During rinsing heating water flows through
the filter, washing sludge and particles collected on the unit floor out through the ball
valve. After 2 - 3 ltrs. of water have run
through, the ball valve must be firmly closed.
Re-open the shut-off valve downstream of
the unit once rinsing is complete.
Check the systems pressure after rinsing as
a top up may be required.
A top up will then bring the unit back to the
correct operating pressure and, where no
automatic fill system is available, be carried
out manually. Pressure levels in the system
and in the expansion vessel should be set
before commissioning the magnetite filter
and checked and adjusted at least once per
year.
14JUDO MAFI
Where retrofitted into an existing system,
the magnetite filter should be rinsed at least
every 14 days until the water removed
becomes visibly clearer. After that, as with
new installations, once at heating start up
and once when the system is shut down is
enough.
5.6Modifications / changes /
(see chapter “Safety information and
dangers due to non-compliance”)
Only original spare parts are to be used!
Arbitrary modifications and changes are
prohibited for safety reasons! They can
impair the function of the magnetite filter and
lead to leaks.
spare parts
Operation
ATTE NTION
5.6.1 Servicing / repair
Before carrying out any work on the magnetite filter, which extends beyond pure operational control, the system must be depressurised! Allow the magnetite filter to cool
down first! Failure to observe this can lead to
an uncontrolled escape of water and therefore lead to scalding and water damage in
the building. Strictly comply with the instructions given in the “Installation” and “Maintenance” chapters.
5.7Stoppages
(see chapter “Safety information and
dangers due to non-compliance”)
If a magnetite filter has to be removed from
the flange or unscrewed, the chapter “Intended use” must always be observed!
– Protect the flange surfaces from dam-
age! Damaged flange surfaces cannot
close tight any longer. As a result, escaping water can damage the building
and installations.
– Store the magnetite filter in frost-free
conditions! Frost can cause any water
contained in the magnetite filter's voids
to freeze and thus cause mechanical
damage to the magnetite filter so that it
leaks at operating pressure or can burst.
Leaking water can cause major damage
to the building. In addition, people near
the magnetite filter can be injured by
breaking off filter parts.
– When restarting the magnetite filter, fol-
low the instructions for a new magnetite
filter.
JUDO MAFI15
Faults
6.Faults
The opening of the units and the replacement of the water pressure charged parts
may only be effected by authorized
personal in order the ensure the unit
security and its tightness.
Help with faults:
FaultCauseRemedy
Heating is cold.
No rinse water.
Rinse water very
dirty.
Magnetite filter
leaks.
A shut-off valve has not been reopened.
A defect in the circulation pump.
The heating system or expansion
vessel is pressureless.
A backflow preventor, gravity brake
or automatic shut-off unit are installed between the magnetite filter
and the expansion vessel in flow direction.
In gas fired systems, shut down often occurs automatically when operating temperature of the heating water has not yet been reached.
Rinse intervals are too long.Reduce rinse intervals!
Open shut-off valve!
Inform the fitter or nearest
customer service centre!
Top up required heating
water! Check expansion
vessel!
Open shut of unit or re-align
place of installation for
magnetite filter more favourably!
Wait for correct water temperature!
Inform the fitter or nearest
customer service centre!
16JUDO MAFI
Maintenance
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ATTE NTION
7.Maintenance
(see chapter “Safety information and
dangers due to non-compliance”)
Always observe the chapter “Intended use”!
7.1Cleaning
(see chapter “Safety information and
dangers due to non-compliance”)
Use only clear, drinking water for
cleaning.
Domestic all-purpose cleaners and glass
cleaners can contain up to 25 % solvents or
alcohol (spirits).
These substances can chemically attack the
plastic parts, which can lead to brittleness or
even fractures.
These kinds of cleaners must therefore
not be used.
8.Warranty and services
In order to comply with the legal warranty
claim, a visual check and rinse of the unit
must be carried out at least once at the beginning and end of the heating period.
Where the heating water has a heavy dirt
load, then the rinse should be carried out
every 2 weeks until a noticeable increase in
clarity has been reached.
A = Fitting length
B = Unit width
C = Height above pipe centre
D = Height below pipe centre
E = Depth to pipe centre
F=
Waste water connection centre
to pipe centre
F1
= Distance
waste water connection
centres
G = Connection dimension waste water
Fig. 10 : Installation dimensions JMFI 1½"
ModelABCDEF F1 G
JMFI 1½" 252 296 141 227 209 151 180 15
All dimensions in [mm] (see fig. 10)
9.5Scope of supply
– Pre-mounted magnetite filter
– Installation and operating instructions
9.6Accessories
– Heating resupply station JHF-F PLUS
(order no. 8060080)
The JUDO HEIFI-FÜL PLUS heating resupply station consists of two integrated shut-off
valves, pressure regulator, manometer and
pipe disconnector, type BA. The integrated
pressure regulator ensures that the pressure in the system remains constant and,
should this drop, then a top up with water is
effected automatically.
JUDO MAFI19
10.Spare parts
1
3
4
5
2
6
7
8
8
8
9
10
11
11
12
13
15
16
17
18
14
Spare parts
20JUDO MAFI
List of spare parts JMFI
Spare parts
Designation
Item
(recommended average replacement interval for wearing parts [*])
--Wearing parts set “Seals ”
consisting of items
(
4, 6, 11, 15)
--Spare parts set “Aeration unit”
consisting of items
(
1)
--Spare parts set “Casing”
consisting of items
(
8, 9)
--Spare parts set “Ball valve”
consisting of items
(
15, 16, 17, 18)
****
Piece(s)
1206038817
1206039038
1206038646
12060456
Order
no.
1Aeration unit1
2Cylinder screw M6x130 (set of 4 pcs)120604626
3Upper cover12060452
4O-ring 52x3,51
5Base unit12060458
6Seal1
7Stopper120604506
8Set of insulating shells1
9Round magnet3
10 Cylinder screw M6x25 (set of 4 pcs)120604462
11 Profiled flange gasket2
12 Splitter, complete12060454
13 Filter bowl12060460
14 Hexagon nut M6 (set of 4 pcs)12060448
15 O-ring 16x2,52
16 Adapter fitting1
17 Union nut1
18 Safety ball valve1
1) AU = accounting unit (Items without AU are only available in a set.)
2) Accounting unit not specified at the time of going to press.
76 Rue de la Plaine des Bouchers (Technosud) • F-67100 Strasbourg
Tel. +33 (0)3 88 65 93 94 • Fax +33 (0)3 88 65 98 49
e-mail : info@judo.fr • judo.fr
Customer service
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24JUDO MAFI
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