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New Control Unit D10 - 1203

New Control Unit D10 - 1203 for GEA Westphalia purifiers

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100% found this document useful (2 votes)

961 views114 pages

New Control Unit D10 - 1203

New Control Unit D10 - 1203 for GEA Westphalia purifiers

Uploaded by

Chief Engineer

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

Safety
Unit Description
Operation
Maintenance
Installation and Connection

Westfalia Separator

Geschäftsbereich Mineraloil Systems GmbH

Mechanische Trenntechnik

Operating instructions

No.: 8555-9001-000

Edition: 1203

Name: Control unit for separators with self-cleaning bowl

Type: D10
2 Westfalia Separator Mineraloil Systems GmbH

Contents subject to changes!

The authors will always welcome comments and suggestions for improving this
documentation. Such comments and suggestions can be addressed to
GEA Westfalia Separator Mineraloil Systems GmbH
Werner-Habig-Str. 1
D-59302 Oelde

© GEA Westfalia Separator

8555-9001-000/1203
Westfalia Separator Mineraloil Systems GmbH 3

Westfalia Separator
Mineraloil Systems GmbH
Geschäftsbereich
Mechanische Trenntechnik

Typ
............................................................................................
Type
Prüf-Nr.
............................................................................................
Control No.
Bemessungsspannung
......... V, 3/AC ................. Hz
Rated voltage
Steuerspannung
.............. VAC ................. Hz ............... VDC
Control voltage
Volllaststrom
................... A
Full-load current
Bemessungsstrom
(größter Motor/Verbraucher)
................... A
Rated current
(largest motor/consumer)
Kurzschlussausschaltvermögen Icn
................. kA
Short-circuit breaking capacity
Schaltplan-Nr.
.........................................................................
Wiring diagram No.
Programm-Nr.
.........................................................................
Program No.
Teil-Nr.
.........................................................................
Part No.

A company of mg technologies group

Installations- und Schutzmaßnahmen sind nach den Bestimmungen des VDE bzw.
des zuständigen EVU auszuführen.
Installation and protective measures are to be taken in accordance with national and
local electric rules and regulations.

This form has to be filled in by the operator.

Please copy the data shown on the nameplate.

8555-9001-000/1203
4 Westfalia Separator Mineraloil Systems GmbH

For Your Safety

• Warning indicating a danger to parts of the unit. Strictly adhere to

instructions marked with this symbol.
This avoids damage to or destruction of the separator or other units.

• Take special care when carrying out operations marked with this
symbol -
otherwise there is danger to life and limb.

• Observe accident prevention regulations.

The local safety and accident prevention regulations apply
unconditionally to the operation of the separator.

• When operating electrical equipment,

certain parts carry dangerously high voltage. Protective measures
must be taken in line with national and local regulations when working
on electrical parts.
Non-compliance with the protective measures can result in serious
injury or damage.
Only suitably qualified specialists are allowed to work on electrical
equipment.

• Comply with the instruction manual.

Follow the instructions given in this manual and the separator manual.

• Operate the separator only in accordance with agreed process

and operating parameters.

• Maintain the separator as specified in the separator instruction

manual.

• Carry out safety checks on the separator

as described in chapter “Safety” in the separator instruction manual.

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Westfalia Separator Mineraloil Systems GmbH 5

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

Liability for the function of the unit unconditionally passes to the owner
or operator, irrespective of existing warranty or guarantee periods in
so far as the unit is improperly maintained or serviced by persons
other than Westfalia Separator service personnel or if the machine is
not used in accordance with the intended use.
Westfalia Separator 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
Separator are not extended by the above.

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6 Westfalia Separator Mineraloil Systems GmbH

Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note

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Westfalia Separator Mineraloil Systems GmbH 7

1 Safety 9

1.1 Foreword................................................................................................ 10
1.2 Intended use .......................................................................................... 10
1.3 Unallowed use ....................................................................................... 11
1.4 Electric wiring......................................................................................... 11
1.5 Explosion protection .............................................................................. 12
1.6 Operation ............................................................................................... 13
1.7 Maintenance and repair ......................................................................... 14
1.7.1 Requirements concerning the service personnel and spare parts ........ 15
1.7.2 Shutting down and "Emergency Off" ..................................................... 15
1.7.3 Storage .................................................................................................. 16
1.7.4 Care instructions.................................................................................... 16

2 Unit description 17

2.1 Function ................................................................................................. 18

2.2 Features................................................................................................. 19
2.3 Areas of application ............................................................................... 19
2.4 Functional diagram ................................................................................ 20
2.5 Technical data ....................................................................................... 21
2.5.1 Control unit D10..................................................................................... 21
2.5.2 Control cabinet....................................................................................... 23
2.5.3 Parts numbers ....................................................................................... 23
2.5.4 Digital inputs/outputs ............................................................................. 24
2.5.5 Analogue inputs/outputs (4 - 20 mA) ..................................................... 25
2.5.6 Special versions..................................................................................... 25
2.6 Design.................................................................................................... 26
2.6.1 Front view .............................................................................................. 26
2.6.2 Internal view........................................................................................... 27

3 Operation 29

3.1 Getting to know the controls .................................................................. 31

3.1.1 Function keys......................................................................................... 32
3.2 System keys .......................................................................................... 34
3.2.1 Soft keys F1-F4 ..................................................................................... 34
3.2.2 Parameter input ..................................................................................... 35
3.3 Switching on the control unit.................................................................. 36
3.4 Password protection .............................................................................. 37
3.5 Menu overview....................................................................................... 38
3.5.1 First level................................................................................................ 38
3.5.2 Second level .......................................................................................... 39
3.5.3 Third level .............................................................................................. 43
3.6 Program flowchart.................................................................................. 45
3.7 User settings.......................................................................................... 46
3.7.1 Display of program data/Main menu (Home)......................................... 46
3.7.2 Setting the user timers........................................................................... 52
3.7.3 Setting the analogue inputs ................................................................... 54
3.7.4 Display of analogue outputs .................................................................. 60
3.7.5 Setting the counters............................................................................... 61
3.7.6 Adjustment of PID controller .................................................................. 66

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3.7.7 Display of separator data / service addresses....................................... 70

3.7.8 Display of counters for operating and alarm messages ........................ 72
3.8 Service adjustments .............................................................................. 75
3.8.1 Display of digital inputs .......................................................................... 76
3.8.2 Display of digital outputs........................................................................ 77
3.8.3 Setting the time of maintenance interval ............................................... 78
3.8.4 Entry of specific separator data ............................................................. 79
3.9 Timer and separator adjustments.......................................................... 82
3.9.1 Basic separator settings ........................................................................ 82
3.9.2 Setting the timers................................................................................... 90
3.10 D10 system menu.................................................................................. 91
3.10.1 Setting of date / time.............................................................................. 91
3.10.2 Display of the fault message buffer ....................................................... 92
3.10.3 Language selection................................................................................ 93
3.10.4 Contrast adjustment............................................................................... 94
3.11 Program settings.................................................................................... 95
3.11.1 Setting the separation time .................................................................... 95
3.11.2 Calculation of separating time ............................................................... 96
3.12 Changing the Micro Memory Card (MMC)............................................. 97
3.13 Memory reset......................................................................................... 98
3.13.1 Connecting the jumper........................................................................... 98
3.13.2 CPU reset .............................................................................................. 99
3.14 Basic setting of evaluation relays RM3 + RM4....................................100
3.14.1 Evaluation relay RM3...........................................................................100
3.14.2 Evaluation relay RM4...........................................................................101

4 Maintenance 103

4.1 Avoiding accidents...............................................................................104

4.2 Requirements concerning the service personnel and spare parts ......104
4.3 Removing faults ...................................................................................104

5 Installation and connection 105

5.1 Installation of control system ...............................................................106

5.2 Connecting the control system ............................................................107
5.3 Centralised control via floating contacts ..............................................108
5.4 Terminal diagrams ...............................................................................109
5.4.1 Terminal box on separator...................................................................109
5.4.2 Analogue inputs ...................................................................................110
5.4.3 Floating contacts..................................................................................110
5.4.4 Digital inputs (terminal strip 1X2 in control cabinet) ............................111
5.4.5 Digital outputs ......................................................................................112

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1 Safety

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10 Westfalia Separator Mineraloil Systems GmbH

1.1 Foreword
The instruction manual is primarily intended for persons entrusted with the task
of operating and maintaining the control system. To assure safe operation it is
therefore imperative that the manual is handed over to these persons.
In the event of any queries please state the model designation and the serial
number (see nameplate inside the control cabinet).
When ordering spare parts, please also state the circuit diagram number
specified which would be helpful for a rapid and correct processing of your
order.

1.2 Intended use

The type D10 control system serves for automatic ejection control and
operations monitoring of mineral oil separators of the series
• OSA
• OSB
• OSC
• OSD
The electronic control unit carries out total bowl ejections with or without
displacement of the centrifuging liquid from the bowl in adjustable periodic time
intervals.
With OSD and OSC separators, the following ejections can be selected:
• Partial ejections
• Total ejections
• Pre-selected partial ejections followed by total ejection
With regard to clearing capacity and ejection losses of the separator, the time-
dependent program cycle demands that the sludge content which can be
centrifuged from the material is not subject to large variations.
The separators equipped with the UNITROL system have two additional
monitoring functions:
• Water content monitoring system - WMS
• Sludge monitoring system - SMS
The separators of the new D generation allow single-stage WMS/SMS operation
when equipped accordingly.
For detailed information regarding the special functions, please refer to the
corresponding chapters in this instruction manual.

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1.3 Unallowed use

Any operation deviating from the intended use shall be considered as unallowed
use.
Unallowed use can not only endanger efficient operation of the control system,
but may also cause damage to the D10 control unit, the centrifuge and other
components. Even danger to life and limb of the user or of other persons cannot
be excluded.
If you wish to deviate from the agreed operation, such other operation has to be
authorised by Westfalia Separator.

1.4 Electric wiring

• Adhere to local regulations for all

matters concerning electrical
systems and equipment.
• In particular, the installation
instructions by Westfalia Separator
shall be observed.
• The frequency and voltage of the
power supply have to match the unit
specification.

Fig. 1

• Set up equipotential bonding.

• Adhere to legal regulations, e.g. within the EU:
– Low-voltage regulation 73/23/EEC,
– Electromagnetic compatibility 89/336/EEC,
– Regulations by the classification societies.

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12 Westfalia Separator Mineraloil Systems GmbH

1.5 Explosion protection

• The local regulations in force for potentially explosive areas shall absolutely
be observed.
The potentially explosive area is an area where an explosive atmosphere is
present or can be expected in such quantities that special measures are
required for design, construction and operation of centrifuges and control
systems.

• Operating the centrifuges/control systems in areas of "zone 0", i.e. in areas

where a hazardous explosive atmosphere is present permanently or for a
long time is not allowed.
• Only such centrifuges/control systems may be used which are equipped for
operation in potentially explosive areas.
• Centrifuges installed in potentially explosive rooms may be operated from a
control panel provided near the centrifuge. The control system in this case is
installed outside of the potentially explosive room.
• In potentially explosive rooms, only devices with an intended use in potentially
explosive atmospheres may be operated.
• All electric equipment belonging to the centrifuge/system such as motor
control units, valve control units, electric heaters, heater control units and
electrically controlled valves shall be provided in the corresponding protective
system and, if provided in the usual protective system, shall be
accommodated in a room which is not potentially explosive.
• Monitoring devices on the centrifuge such as pressure and flow control
devices and temperature switches shall be connected to intrinsically safe
EEx(i) circuits.
• Take protective measures according to the measures for primary explosion
protection in the near vicinity of the centrifuge/control system (ventilation etc.).

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1.6 Operation

• Adhere to the instructions stated in

chapter “Operation”.
• Observe the nameplate.
Check if the rated and control
voltages match the connection data
of the control system.

Fig. 2

If unusual noises or vibrations occur

on the centrifuge:
• Shut down centrifuge immediately
by "Emergency Off".
• Never initiate a bowl ejection!
• Evacuate the room.
• Get back into the room only after the
centrifuge has come to a standstill.

Fig. 3

• The bowl must not be used without

liquid feed for more than 15 minutes
as this may result in an inadmissible
heating of the bowl material.

In energy-related plants:
• Activate cooling water program (see
chapter 3.8.1 "Basic separator
settings").

Fig. 4

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1.7 Maintenance and repair

Maintenance of the control system in good time and replacement of worn or
damages system components is a must for reliable operation.

Maintenance and repair work may only be carried out by the operator to the
extent described in the present manual.

Maintenance and repair work not described in the present manual may
only be carried out by the manufacturer or by the "Central repair
workshops" authorised by him.
We recommend having the control system checked regularly by our specialists.
These checks help maintain the operational reliability and avoid unexpected
operational standstills.

Prior to performing any maintenance

and repair operations:
• Disconnect all electrical systems
and equipment parts from the power
supply by actuating the main switch.
• Secure the unit against accidental
reconnection to power using locking
devices.

Fig. 5

Start maintenance and repair work only after the centrifuge has come to a
complete standstill!
Please refer to the separator instruction manual for how to check if the
separator has come to a standstill.

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1.7.1 Requirements concerning the service personnel and spare parts

• Use genuine spare parts by Westfalia

Separator only.
The use non-genuine parts results in:
– safety risks,
– reduced service life and availability,
– increased service needs.
If a safety risk results, the persons not
complying with this information might be subject
Fig. 6 to prosecution under criminal law. Westfalia
Separator shall not assume any liability or give
any warranty in such cases.
• Make sure that only properly qualified personnel is entrusted with maintaining
the unit. This is the case with the service personnel of Westfalia Separator or
personnel trained by Westfalia Separator.
An inadequately maintained/installed machine holds a high safety risk for the
operating personnel.

1.7.2 Shutting down and "Emergency Off"

Depending on its version, the control cabinet is equipped either with an
Emergency Off button or with a main switch with Emergency Off function which
allows shutting down all drives in case of danger or of abnormal separator
operation.
Together with external and internal Emergency Off switches, the separator is
shut down in a controlled way with two total ejections.
When actuating the main switch with Emergency Off function, the complete
control system is disconnected from the power supply. There is no separator
ejection.

Note:
If the unit is equipped correspondingly, the shut-down process can be
accelerated by a pneumatic brake and a safety water function.

• When shutting down the unit,

observe the chapter "Operation".

Fig. 7

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1.7.3 Storage
• The control system and the accessories (e.g. spare parts, tools)
must be stored in a dry place free from dust, vibrations and frost.
• Protect against excessive heat!
Recommended storage temperature: + 2 to + 45 °C (35.6 – 113 °F)
• Outdoor storage is not allowed!

1.7.4 Care instructions

Do not clean the D10 control unit surface (display, keyboard) using aggressive
or acid-containing substances (pH-value 6-8, surfactant content < 5 %, free
from aromatic substances and ethanol).

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2 Unit description

2.1 Function ................................................................................................. 18

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2.1 Function
The illuminated 4-line LCD display provides information about the operating and
fault conditions of the separator and displays corresponding process data,
depending on programming.
In addition to the control cabinet and the D10 control unit, the control system
includes all complete components which, following the installation of electrically
connected equipment items, are subject to the influence of the control system
either with a controlled or a monitoring function.
This includes:
• the product feed
• the water connection
• the control water connection
• with UNITROL additionally
– the circulation and water discharge valve
– the water sensor
– and/or the pressure control device for the bypass line in SMS function
Options to be ordered separately:
• PT100 sensor with a two-wire circuit for min./max. monitoring in the product
feed line
• Filling level switch for monitoring the water discharge
• Process-dependent control of an external feed pump
• Filling level switch for monitoring the sludge tank
• Min./max. level switch for controlling a sludge pump
• Signal horn for acoustic alarms
The standard control system is designed for single operation of separating or
clearing separators.

If required, series operation can be pre-selected with two-stage HFO operation.

This requires a corresponding pipework between the separators and the MPI
interfaces of at least two control systems must be wired according to chapter
5.4 "Terminal diagrams".

The D10 control unit is in a ready-for-installation condition, is fitted into the door
of the control cabinet and is programmed for the required control job.

Modifications to the program by the operator are not allowed.

The operator can use the keyboard to make the following settings:
• Machine-specific program preselection
• Timer values
• Counter values

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2.2 Features
The D10 control unit has the following features:
• Display for machine observation and operation
• Function keys with LED status indication
• Control voltage 24V
• High functional reliability
• Long service life
• User program on Micro Memory Card (MMC)

2.3 Areas of application

Application Description
Single - standard The separator is operated in single operation
as standard (-91-).
WMS The separator is operated with an activated
Water Content Monitoring System (-01-) (for
(Water Content Monitoring
more detailed information please refer to the
System)
separator instruction manual).
SMS-HFO The separator is operated with an activated
Sludge Monitoring System (-36-) (for more
(Sludge Monitoring System)
detailed information please refer to the
separator instruction manual).
SMS-LO The separator is operated with an activated
Sludge Monitoring System (-96-) (for more
(Sludge Monitoring System)
detailed information please refer to the
separator instruction manual).
WMS series (-01-) The separator is operated as the first stage in
series operation with a separator with SMS.
Signal exchange is via the MPI interface.
SMS series (-36-) The separator is operated as the second stage
in series operation with a separator with WMS.
Signal exchange is via the MPI interface.
WMS/SMS -HFO single- In heavy oil treatment, the separator is
stage operated with an activated Water Content
Monitoring System (-01-) and Sludge
Monitoring System (-36-).
WMS/SMS -LO single- In heavy oil treatment, the separator is
stage operated with an activated Water Content
Monitoring System (-01-) and Sludge
Monitoring System (-96-).

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2.4 Functional diagram

Fig. 8

A Water
B Product discharge
C Product feed

1 Water pressure reducer

2 Feed valve, complete with solenoid valve for filling, displacement and
control water
3 Control system and motor control unit for separator
- Feed pump motor control unit
- Sludge pump motor control unit
4 Terminal box (mounted on separator)
5 Water sensor
6 Circulation valve
7 Pressure control device for sludge monitoring
8 Water discharge valve
9 Pneumatic 3/2-way valve with manual adjustment and control air
solenoid valve (installed in the separator product feed line)
10 PSL pressure control device for product discharge
11 PSH pressure control device for product discharge

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2.5 Technical data

2.5.1 Control unit D10
Technical data
Type designation 6ES7613 - 1SB00 - 0AC0
Dimensions (width x height x 215 x 165 x 88 mm
depth)
Installation / cut-out dimensions 202 x 152 mm (tolerance +1 mm )
Weight 1.35 kg
Display, LED background lighting LCD display, background-lighted LEDs, 4
lines with 20 characters each, character
height 5 mm
Keyboard 23-key membrane keyboard with 11
integrated LEDs
Interfaces Standard MPI interface for programming
device and network, P bus for S7 extension
modules
Supply voltage DC 24 V, range DC 20.4; DC 28.8 V
Protected against polarity reversal yes
Power interruption > 20 ms
Current input (in) 2.4 A
Integrated main memory 48 kByte
External memory Plug-in Micro Memory Card (MMC)
Buffer Ensured by Micro Memory Card (MMC), no
battery required
Configuration software Step 7 from version 5.1; service pack 4
HMI software Integrated in Step 7
Inputs • 24 digital, DC 24 V
• 4 analogue, 4-20 mA / 0-10 V
• 1 PT 100
Outputs • 16 digital, 0.5 A each, total current 4 A
• 2 analogue, 4-20 mA
Safety standard DIN EN 61131-2/IEC 61131-2
Enclosure • Unit front: IP 65 according to IEC 60529,
NEMA 4X
• Unit housing: IP 20 according to IEC
60529

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Technical data
Electromagnetic compatibility A according to EN 55011

Climatic conditions • Tested according to IEC 60068-2-1, IEC

60068-2.2
• Operation: 0 - 55 °C when installed
vertically
• Storage: -20 °C to +70 °C
• Humidity: 5 - 95 % at 25 °C
Mechanical ambient conditions • Vibration operation: Tested according to
IEC 60068-2-6, IEC 60068-2.6
• Vibration storage/transport: 10 to 58 Hz,
amplitude 0.075, 5 to 9 Hz
• Shock operation: Half-sine: 150 m/s2 (15
g), 11 ms, 18 shocks
• Shock storage/transport: 250 m/s2 (25 g),
6 ms, 1000 shocks
Fire resistance • Plug connectors FV2 acc. to IEC 60707
• Basic connector FV0 acc. to IEC 60707
Approvals • CE (EC directive EMC 89/336/EEC)
• UL (Underwriters Laboratories UL 508)
• CSA (Canadian Standard Association
C22.2 No.142)
Type tests / classification societies • GL (Germanischer Lloyd)
• LRS (Lloyds Register of Shipping)
• DNV (Det Norske Veritas)
• BV (Bureau Veritas)
• ABS (American Bureau of Shipping)
• RINA (Registro Italiano Navale)
• NK (Nippon Kaigi Kyokai)

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2.5.2 Control cabinet

Technical data
Mains voltage 115/230 VAC (± 10 %), selectable
Frequency 50 to 60 Hz
Power consumption (max.) 100 VA
Control voltage 24 VDC
Supply line fuse 16 A (slow-blow)
Ambient temperature 0 to 55 °C
Housing Painted steel sheet, RAL 7032
Special version: stainless steel
Enclosure IP 55 (when installed properly in
accordance with the instructions stated in
chapter 5 “Installation and connection”)
Dimensions (width x height x 380 x 600 x 350 mm
depth)
Cable entry From below through the cable glands
Electrical design in accordance with EN 60204-1 (optional core identification)
Ambient conditions 3C2 in accordance with EN 60721-3-3

2.5.3 Parts numbers

Name Number
Control unit C7-613 0005-4050-380
Installation frame 0005-4278-040
Micro Memory Card (MMC) 0005-3668-010
Connector set 0005-4050-420
Service pack 0005-4050-420
Instruction manual 8555-9000-000

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2.5.4 Digital inputs/outputs

Name Connection Function
Inputs DI 0.0 Separator in operation
DI 0.1 Separator fault
DI 0.2 PSL product discharge
DI 0.3 PSH product discharge
DI 0.4 FSH water discharge
DI 0.5 WMS-UNITROL
DI 0.6 SMS-UNITROL
DI 0.7 LSHH sludge tank
DI 1.0 Feed pump "operation"
DI 1.1 Feed pump "fault"
DI 1.2 Sludge pump "operation"
DI 1.3 Sludge pump "fault"
DI 1.4 LSH sludge tank for pump start
DI 1.5 LSL sludge tank for pump stop
DI 1.6 Vibration level 1
DI 1.7 Vibration level 2
DI 2.0 Emergency stop
DI 2.1 - DI 2.7 Spare for options
Outputs DO 0.0 Product valve
DO 0.1 Water valve
DO 0.2 Control water valve
DO 0.3 Steam valve / heater interlock (option)
DO 0.4 Circulation valve "UNITROL"
DO 0.5 Water discharge valve "UNITROL"
DO 0.6 Lamp test (option)
DO 0.7 Common alarm
DO 1.0 Separator "OFF"
DO 1.1 Feed pump "OFF"
DO 1.2 Sludge pump "OFF"

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2.5.5 Analogue inputs/outputs (4 - 20 mA)

Name Connection Function
Inputs AI 01 Motor current and ejection
monitoring
AI 02 Bowl speed (option)
AI 03 Min./max. product temperature
AI 04 Product temperature PID controller
PT 100 PT-100 product temperature
Outputs A00-I Motor current
A01-I Temperature

2.5.6 Special versions

Special versions deviating from the versions described in this manual can be
supplied:
• The housing can have other dimensions.
• The housing can be made of stainless steel.
• Parts of the control system can be integrated in a compact control cabinet
(e.g. with separator motor control unit etc.) or in a central control unit.

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2.6 Design
The design may vary, depending on the scope of supply.
The control system is assembled (ready for use), wired (ready for connection)
and complies with the regulations stated in EN 60204.

2.6.1 Front view

5 4

Fig. 9

1 Lock (lockable)
2 Control unit D10
3 OFF/ON pushbutton for separator
4 OFF/ON pushbutton for feed pump
5 MANUAL/0/AUTOMATIC selector switch for sludge pump
6 Main switch

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2.6.2 Internal view

Fig. 10

1 1X1 terminal strip (terminal 1 – 24)

2 Main switch
3 1X2 terminal strip (terminal 65 -92)
4 Thermistor-type motor protection
5 Contactor relay
6 Motor circuit-breaker
7 Automatic circuit breaker
9 Current transformer
10 Control transformer for heater and ventilation (option)
11 Control voltage transformer

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28 Westfalia Separator Mineraloil Systems GmbH

Fig. 11

12 Power supply for PLC and valves

13 Control unit D10
14 Buffer amplifier for analogue output (option)
15 Coupling relay
16 WMS relay
17 Terminal strip 1X3
18 Control pushbuttons
19 Sludge pump selector switch
20 Terminal strip 1X2

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3 Operation

3.1 Getting to know the controls .................................................................. 31

3.1.1 Function keys......................................................................................... 32
3.1.2 System keys .......................................................................................... 34
3.1.3 Soft keys F1-F4 ..................................................................................... 34
3.1.4 Parameter input ..................................................................................... 35
3.2 Switching on the control unit.................................................................. 36
3.3 Password protection .............................................................................. 37
3.4 Menu overview....................................................................................... 38
3.4.1 First level................................................................................................ 38
3.4.2 Second level .......................................................................................... 39
3.4.3 Third level .............................................................................................. 43
3.5 Program flowchart.................................................................................. 45
3.6 User settings.......................................................................................... 46
3.6.1 Display of program data/Main menu (Home)......................................... 46
3.6.2 Setting the user timers........................................................................... 52
3.6.3 Setting the analogue inputs ................................................................... 54
3.6.4 Display of analogue outputs .................................................................. 60
3.6.5 Setting the counters............................................................................... 61
3.6.6 Adjustment of PID controller .................................................................. 66
3.6.7 Display of separator data / service addresses....................................... 70
3.6.8 Display of counters for operating and alarm messages ........................ 72
3.7 Service adjustments .............................................................................. 75
3.7.1 Display of digital inputs .......................................................................... 76
3.7.2 Display of digital outputs........................................................................ 77
3.7.3 Setting the time of maintenance interval ............................................... 78
3.7.4 Entry of specific separator data ............................................................. 79
3.8 Timer and separator adjustments.......................................................... 82
3.8.1 Basic separator settings ........................................................................ 82
3.8.2 Setting the timers................................................................................... 90
3.9 D10 system menu.................................................................................. 91
3.9.1 Setting of date / time.............................................................................. 91
3.9.2 Display of the fault message buffer ....................................................... 92
3.9.3 Language selection................................................................................ 93
3.9.4 Contrast adjustment............................................................................... 94
3.10 Program settings.................................................................................... 95
3.10.1 Setting the separation time .................................................................... 95

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3.10.2 Calculation of separating time ............................................................... 96

3.11 Changing the Micro Memory Card (MMC)............................................. 97
3.12 Memory reset......................................................................................... 98
3.12.1 Connecting the jumper........................................................................... 98
3.12.2 CPU reset .............................................................................................. 99
3.13 Basic setting of evaluation relays RM3 + RM4....................................100
3.13.1 Evaluation relay RM3...........................................................................100
3.13.2 Evaluation relay RM4...........................................................................101

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3.1 Getting to know the controls

6 1 2

5 4 3

Fig. 12

The D10 control unit is integrated into the control cabinet door. The operating
interface consists of:
1 Softkeys F1-F4 (depending on the current display)
2 Display (text display)
3 System keys
4 Function keys (when the Edit key has been pressed, numerical values
can be entered.)
5 Status and fault indicator
6 Operating mode selector (start/stop of CPU)

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3.1.1 Function keys

The function keys have a global function: The actions which can be triggered
are independent of the text on the display. They each incorporate an LED which
provides information on the state of the respective function.
•
Key Key designation Description
Separation program "OFF" In separating mode, this key closes the feed valve and ejects
the bowl content.
With OSC/OSD separators, there are two automatic total
ejections.
The LED lights up when the ejections are carried out.
Separation program "ON" This key starts the separation program.
When the ejection program is complete, the feed valve is
opened.
When falling below the min. separating temperature or if the
"LSHH sludge tank" level switch sends a signal, a program start
is not possible.
The LED goes on when the ejection and/or separation program
is activated.
Lamp test This key starts a function test of the LEDs integrated in the keys
and of any possible external indicator lights.
The LEDs of status and fault displays are not tested.

Series operation With series operation of HFO separators, two D10 control
systems can be pre-selected for this type of processing within
the MPI network. To activate series operation, actuate the
"SERIES" key on both D10 control units.
The LED goes on when series operation is activated.
Home Direct jump to main menu (see chapter 3.6.1 "Display of
program data/Main menu (Home)")

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Key Key designation Description

Fault message screen This key calls up the screen displaying an overview of the
current fault messages or the fault message buffer.
When a fault occurs, a list of measures for removing the fault
appears after acknowledging the fault with the Enter key.
If the LED flashes, information for removing the current fault is
available after pressing F1.
The LED flashes as long as an unacknowledged fault message
is queued.
PID controller If the system is equipped accordingly, the product feed and
temperature control can be activated when the "PID controller"
key is pressed.
The LED lights up when the control system is in automatic
mode.
For testing operation using manual adjustments, first deactivate
the control system at the PID controller" key. In the
corresponding screen menu (see chapter 3.6.6 "Adjustment of
PID controller"), close the motor valve using the softkeys F2/F3.
Feed pump status This key has no function. The LED in this key indicates the
current feed pump status.
• Continuous light: Operation
• Slowly flashing: Fault by motor protection
• Fast flashing: Slowing-down phase
Sludge pump status This key has no function. The LED in this key indicates the
current sludge pump status.
• Continuous light: Operation
• Slowly flashing: Fault by motor protection
Separator status This key has no function. The LED in this key indicates the
current separator status.
• Continuous light: Operation
• Slowly flashing: Fault by motor protection
• Fast flashing: Start-up phase

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3.1.2 System keys

Key Key designation Description

Cursor up/down/right/left These keys are used to select the menus.

If there are input fields in a menu, these keys are used to move
the cursor from one field to the other. The next menu is selected
after the last input field.
These keys are also used to navigate through the fault
messages in the message buffer or on the message level.

Esc (cancel) This key is used to cancel field inputs provided that they have
not been confirmed using the Enter key.
If the ESC key is pressed in a menu, the program returns to the
preceding menu or to the message level.
No further return is possible on the message level.

Enter This key

• confirms and completes an entry;
• acknowledges an active fault message;
• provides the transition from the message to the image level.

Edit This key is used to edit parameters or timer/counter setpoints.

The LED goes on when the editing mode is activated.

3.1.3 Soft keys F1-F4

Key Key designation Description

Soft keys The soft keys have a local function. The actions which can be
triggered depend on the pictures currently displayed and are
assigned to the pictures.

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3.1.4 Parameter input

Numerical input e.g. for passwords or setpoint changes is by means of the
function keys.

Fig. 13

The corresponding value (1) can be seen on the right above the respective
function keys.

Note:
If by mistake you failed to properly actuate the Edit key when entering
parameters, the function of the respective function key is active. You may now
possibly change current separator operation.
Actuating the wrong key one more time brings you back to the initial separator
function condition.

If entries are possible in a menu, this mode can be identified by the flashing
cursor in the display.
Editing values:
• Press Edit key, the LED in the Edit key lights up.
• Enter the new value and/or the password using the function keys.
• Complete your entry by pressing the Enter key.

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3.2 Switching on the control unit

When you switch on the control unit,
the screen content shown on the left is
C7-613 Firmw.:V1.01 first displayed.
Bootl.:V1.01

> Startup <

Fig. 14

Any required data are read in from the

Micro Memory Card (MMC).
$ 002 transfer

> Downloading User-<

> Data <

Fig. 15

Then the unit starts up with the display

shown on the left. Start-up takes about
Westfalia Separator 3 minutes.
Mineraloil Systems • Press the Enter key.
please press •
>> ENTER <<

Fig. 16

The main menu is displayed. From this

Fig. 17

Note:
To avoid long start-up times, the D10 control unit should be supplied with power
even if the separator is not used.

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3.3 Password protection

Certain entries and functions are possible only after entering a password.
• Company-related basic settings
– Password level 1
• Service
– Password level 2
• Read-out of CPU data
– Password level 3
You will be requested to enter the required password in a window.
Note:
The password is available from Westfalia Separator upon request.

Proceed as follows when being

prompted to enter the password:
Password login: • Press the Edit key.
Level : 0 – The LED in the Edit key goes on.
Password: ...... • Enter the password using the
function keys.

Fig. 18

• Press the Enter key. The password

is accepted.
Password login: – The program jumps to password
Level : 1 level 1.
Password:....... • Press the Enter key one more time.
– The program returns to the
preceding menu.
• Press the arrow key and the first
Fig. 19 password-protected menu is called
up.

If no operation is performed within two minutes, the program automatically

returns to input level 0 (logout). The password has to be re-entered in order to
use the program again.

However, the menu which is called up at that time is not protected. This means
that unauthorised persons may carry out changes in this menu.
To protect the D10 control unit from unauthorised access, you should go back in
the menus until you reach the openly accessible menu section.

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3.4 Menu overview

3.4.1 First level

*1 No password required
*2 Password level 1
*3 Password level 2
Fig. 20

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3.4.2 Second level

Setting of operator timers

Display of current
program setting (HOME)

*1 No password required
Fig. 21

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Timer list 2:
Setting of times for timers

Timer list 1:
Setting of times for timers

Separator settings

*2 Password level 1
Fig. 22

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Setting the time of maintenance

interval

Display of digital outputs

Display of digital inputs

*3 Password level 2
Fig. 23

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Language selection

Fault message history

Setting of time and date

*1 No password required
Fig. 24

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3.4.3 Third level

ALARM_C
| SERVICE Not used!
| INFO
| |

Not used!

Entry of separator serial number and

commissioning date and display of
control unit-specific data and
service addresses

Display of counters for operating and

alarm messages

Fig. 25

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Setting of counter for flushing, partial

ejection and SMS filling

Display of analogue outputs for motor

current and temperature

Display of analogue inputs and entry

of limit values

Fig. 26

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3.5 Program flowchart

Separator has been

switched on

"Bypass operation" "Standby"

Separation process is interrupted by Separator is at operating speed,
previous ejection program separation process can be started with
the preselected operating mode
and/or selected separator.

*1, *2

“Separate status”
Separation is started. The individual
program steps are processed with the
times set, depending on the selected
operating mode.

*1 or through external signal

*2 or through fault

Fig. 27

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3.6 User settings

3.6.1 Display of program data/Main menu (Home)
When you switch on the D10 control
USER unit, the main overview shown on the
left first appears after acknowledging
| ADJUSTM. with the Enter key and starting up.
| | SERVICE To call up the user settings, carry out
| | | D10 the following steps:
• Call up the "User adjustments"
menu using the F1 key.
Fig. 28

The "User adjustments" overview is

Fig. 29

The main menu is displayed.

Program: Operation • The main menu can be called up
directly from any other menu using
Step: Feed open the Home key.
Product temp.: 93°C • Further program settings can be
Separ. time 7200sec called up from the main menu, using
the down arrow key.
Fig. 30

The descriptions of the individual

program settings are provided on the
Sep type: OSD-60
following pages.
Motor curr.: 40.5 A
Start time: 0 sec
Mode: Single

Fig. 31

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Status: Feed pump

Operation
Status: Sludge pump
OFF

Fig. 32

Status: Separator
Operation
Status:Heaterrelease
ON:

Fig. 33

Partial ejection:
> OFF <

Fig. 34

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Program: Operation
Step: Feed open
Product temp.: 93°C
Separ. time 7200sec

Fig. 35

1st menu line

The current program cycle status is displayed.
Display Meaning
OFF Separator has not been switched on.
Separator is in the start-up phase; starting a
Start-up
process is not possible.
Standby: The separator is at operating speed,
Standby
the separating process can be started.
The separator is in the process, the product feed
Separation
is open or the ejection program is running.
The motor contactor has responded, the
separator has been disconnected from the mains
PTC alarm
power supply and the feed valve has been
closed.

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2nd menu line

Depending on the selected operating mode and/or selected separator, the
current program cycle ("step") is shown in the display.
The display texts following each other can be shown as described below (see
also separate documentation "Timer and parameter lists").
Display Meaning
Circulation operation: The feed valve is in
recirculation mode. The separator is in the start-
Circulation operation
up or fault mode and/or the process has not
been initiated.
Waiting The separation process has been initiated.
The bowl content is displaced without losses
Displacement through the opening of the displacement water
valve.
Waiting after After displacement, there is a waiting time of
displacement 5 seconds.
The sludge space of the bowl is emptied by
Total ejection
actuating the control water valve.
The speed drop occurring during ejection is
Waiting for speed
compensated.
The filling process builds up the necessary water
Filling seal in the VARIZONE and UNITROL separators
in the -96- mode.
After the filling process, there is a waiting time of
Waiting after filling
5 seconds.
Feed open The separation process is activated.
Sensor test The individual sensors are checked.

3rd menu line

Display Meaning
The current product feed temperature is
Product temperature
displayed in degrees centigrade.

4th menu line

Display Meaning
The separating time count-down is displayed in
Separating time seconds. When "0" is displayed, the ejection
program is started automatically.

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• Further program settings can be

called up from the main menu, using
Sep type: OSD-60 the down arrow key.
Motor curr.: 40.5 A
Start time: 0 sec
Mode: Single -01

Fig. 36

1st menu line

The separator type currently selected (OSA-X, OSB-X, OSC-X, OSD-X) is
displayed. The separator type is set at the factory.
2nd menu line
The current separator current is displayed. The current values are different in
the start-up, ejection and operating cycles.
3rd menu line
During the separator start-up phase, the start time count-down is displayed in
seconds. When "0 sec" is displayed, the separator is ready for operation. Pre-
setting is carried out on timer 10.
4th menu line
Display of pre-selected separator operating function (mode). The separator
operating mode is set at the factory. The following displays are possible:

Application Description
The separator is operated in single operation
Single - standard
as standard (-91-).

WMS The separator is operated with an activated

Water Content Monitoring System (-01-) (for
(Water Content Monitoring more detailed information please refer to the
System) separator instruction manual).
The separator is operated with an activated
SMS-HFO Sludge Monitoring System (-36-) (for more
(Sludge Monitoring System) detailed information please refer to the
separator instruction manual).
The separator is operated with an activated
SMS-LO Sludge Monitoring System (-96-) (for more
(Sludge Monitoring System) detailed information please refer to the
separator instruction manual).

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Application Description
The separator is operated as the first stage in
WMS series (-01-) series operation with another separator. Signal
exchange is via the MPI interface.
The separator is operated as the second stage
SMS series (-36-) in series operation with another separator.
Signal exchange is via the MPI interface.
In heavy oil treatment, the separator is operated
WMS/SMS -HFO single- with an activated Water Content Monitoring
stage System (-01-) and Sludge Monitoring System
(-36-).
In heavy oil treatment, the separator is operated
WMS/SMS -LO single- with an activated Water Content Monitoring
stage System (-01-) and Sludge Monitoring System
(-96-).

Status: Feed pump

Operation
Status: Sludge pump
Operation

Fig. 37

Status: Separator
Operation

Fig. 38

Status displays for feed pump, sludge pump and the separator. Possible status
displays include:
• OFF
• Operation
• Fault

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3.6.2 Setting the user timers

The timer lists make three groups available:
• Timer 1
• Timer 2
• User timers
Only the menu "User timers" allows changing some process-dependent timer
values without entering a password. The two other groups should only be
modified by service personnel.

Attention: Change timer values only when timer is passive. When active, the
pre-set time will time out first, and the change will only become valid upon the
next activation. All set times run backward from the entered setpoint and
activate the programmed function after the time has elapsed.

Note:
Usually, a user timer needs to be changed only if the product is subject to
variations in pollution or if the displacement and filling water pressure varies
(measure the litre capacity from time to time and compare with the
specifications in the separator instruction manual, adapt time if required).
When switching to series operation, set the transition time of timer 11 to a
minimum value of approx. 70 sec. This avoids a PAL alarm on the product
discharge side of the second separator.
When starting the separator during a slow-down phase at the corresponding
speed, timer 10 can be set to 0 for a short time in order to reduce the re-starting
time. After this, ensure that the factory setting value is entered again. All times
have been pre-set to the corresponding separator type at the factory and are
adapted to local conditions during commissioning.

To set the user timers, carry out the

Fig. 39

The "User adjustments" overview is

Fig. 40

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Note:
A letter appears ahead of the respective value in the displayed timer. These
letters have the following meaning:
• P: Setpoint (preset)
• A: Actual value
The individual values can now be
called up one after the other by
Operator Timer pressing the down arrow key.
Changing the timer setting:
T20: Separation • Press the Edit key.
P:7200sec A:1234sec – The LED in the Edit key goes on.
• Enter the new timer value using the
function keys.
Fig. 41 • Press the Enter key. The new value
is accepted.
• Go to the next timer value using the
arrow keys.

Actual
Timer Meaning Setpoint
value
T20 Separation 7200 s
T01 Displacement - UNITROL with WMS
T 02 Filling - UNITROL with WMS
T10 Separator start-up 600 s
T11 Alarm bypass 60 s min.
with 2-
stage
operation

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3.6.3 Setting the analogue inputs

Fig. 42

The overview for users is displayed.

Fig. 43

The overview for the "Settings" menu

Fig. 44

The individual values can now be

called up one after the other by
AI0: Motor current pressing the down arrow key.
1U3 6/7 10.5 A Changing the setting:
Ejection monitoring • Press the Edit key. The LED in the
Offset: 2.0 A Edit key goes on.
• Enter the new value using the
function keys.
Fig. 45 • Press the Enter key. The new value
is accepted.
• Go to the next timer value using the
arrow keys.

Note:
An explanation on the setting of the analogue inputs can be found on the
following pages.

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Ejection monitoring:

AI0: Motor current

1U3 6/7 10.5 A
Ejection monitoring
Offset: 2.0 A

Fig. 46

Input Function Terminal Value

AI 0.0 Motor current 1U3 6/7 10.5 A
Ejection monitoring
Offset 2.0 A

When in separation operation, start a total ejection with the start key and
observe the ejection current in the corresponding display. The ejection current
normally is higher than the nominal current in the separating program. Enter the
difference between the ejection current and the separating current (e.g. 2.0 A)
as offset value.
Ejection monitoring is not operative when 0.0 A was entered as offset value.
However, this should be done in exceptional cases only.

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Bowl speed display (option):

AI1: Bowl speed

1U2 12+/13- 6000 rpm
Max: 8000 rpm
(option)

Fig. 47

Input Function Terminal Einstellwert

AI 0.1 Current bowl speed 1U2 6000 rpm
12+/13-
Max. bowl speed 8000 rpm

As an option, the bowl speed can be shown on the display. The separator and
the control cabinet must be equipped accordingly for this function. A speed
initiator on the machine and a transmitter relay in the control cabinet are
required for this.
In the max. bowl speed line, the maximum speed according to the separator
manual is entered during commissioning. This activates the corresponding
resolution of speed calculation.

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Temperature monitoring (4-20 mA signal):

AI2:Product Temp.
1X2.61/63/SC 95°C
Min: 60°C
Max: 100°C

Fig. 48

Input Function Terminal Einstellwert

AI 0.2 Product temperature 1X2 . 95 °C (203 °F)
61/63/SC
Min: 85 °C (185 °F)
Lowest limit value for
separation temperature
monitoring
Max: 105 °C (221 °F)
Highest limit value for
separation temperature
monitoring

The D10 control unit works with two different temperature monitoring systems.
The measuring principle described here requires a 4-20 mA signal and was
used with the OSC types in the past. A temperature range from 0 to 120
degrees is available here.
When falling below the min. separation temperature, starting the separation
program is not possible. Observe the corresponding information on the display.
When using PT 100 sensors, the display described on this page has no
function.

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Temperature monitoring (PT100 signal):

PT100 Product Temp.

1X2.78/79 95°C
Min: 60°C
Max: 100°C

Fig. 49

Input Function Terminal Setting value

PT100 Product temperature 1X2.78/79 95 °C (203 °F)
Min: 85 °C (185 °F)
Lowest limit value for
separation temperature
monitoring
Max: 105 °C (221 °F)
Highest limit value for
separation temperature
monitoring

The D10 control unit has a direct PT 100 input with a two-wire connection.
When falling below the min. separation temperature, starting the separation
program is not possible. Observe the corresponding information on the display.
When using combined thermoelements with a 4-20 mA output, the display
described on this page has no function.

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PID temperature control (option):

AI3:PID Controller
1X2.76/77 95°C
Kp: 250
Tn: 24

Fig. 50

Input Function Terminal Setting value

AI 0.3 PID controller 1X2 . 76/77

The D10 control unit is equipped with a software PID controller which allows
controlling the product temperature in connection with optional hardware
components.
The PID function is pre-selected by pressing the PID key.
The setting of the control response and/or adaptation of the controller to local
conditions is done in the chapter 3.6.6 "Adjustment of PID controller".

PID temperature control (option):

Temp. recording
Peak: 120°C
Bowl monitoring
Offset: 2.0 A

Fig. 51

Display Meaning
Temp. recording The highest occurred temperature is recorded for
evaluating operating conditions.
Bowl monitoring The closing water pulses for bowl closing during
separation is checked by a current measurement.
3 seconds before the water pulse the current is
measured automatically and compared with the value
obtained 3 seconds after the water pulse. The allowed
difference is entered in the display as an offset value.
When the offset value is exceeded, an alarm message
is generated.

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3.6.4 Display of analogue outputs

The process variables such as separator current and product temperature can
be transmitted to a higher-ranking control system as a 4-20 mA signal (provide
an amplifier with electrical isolation for transmission).
To display the analogue outputs, carry out the following steps:
• Call up the "User adjustments"
menu using the F1 key.
USER
| ADJUSTM.
| | SERVICE
| | | D10

Fig. 52

The "User adjustments" overview is

Fig. 53

The overview for the "Settings" menu

Fig. 54

A00.1: Motor current

1X2.93/94/SC 1.9 A
A00.2: Temperature
1X2. 91/92/SC 3.0 A

Fig. 55

Output Function Terminal Signal

A00.1 Motor current (option) 1X2. 93/94/SC 4 - 20 mA
A00.2 Temperature (option) 1X2. 91/92/SC 4 - 20 mA

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3.6.5 Setting the counters

Fig. 56

The "User adjustments" overview is

Fig. 57

The overview for the "Settings" menu

Fig. 58

The individual values can now be

called up one after the other by
Z 1: Flush. counter pressing the down arrow key.
Changing the counter:
P: 10 • Press the Edit key. The LED in the
A: 4 Edit key goes on.
• Enter the new value using the
function keys.
Fig. 59 • Press the Enter key. The new value
is accepted.
• Go to the next timer value using the
arrow keys.

Note:
An explanation regarding the individual counters can be found on the following
pages.

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Flushing counter:

Z 1: Flush. counter
P: 10
A: 4

Fig. 60

Setpoint Actual
Counter Meaning
(P) value (A)
Z1 Flushing ejection 10

The number of total ejections which are carried out until an automatic flushing
ejection with water is to be started is entered into the entry field (P). When
operating the unit without flushing counter, set the counter to "0".
The actual value (A) is reduced by one point upon each completed total
ejection. When the value "0" has been reached, the desired flushing ejection is
carried out after the next total ejection.

Note:
The flushing counter will only react to completed total ejections. Partial ejections
will not be counted. Ejection monitoring is not active during flushing ejections.

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Partial ejection:

Z 2:Partial ejection
Only OSC/D types
P: 8
A: 2

Fig. 61

Setpoint Actual
Counter Meaning
(P) value (A)
Z2 Partial ejection of OSC/D types 8

When the control water system is modified accordingly, partial ejection

programs can also be used on the OSC and OSD separator types if desired.
The number of partial ejections which are carried out until a double total ejection
with water is to be started is entered into the entry field (P).
The actual value (A) is reduced by one point upon each completed partial
ejection. When the value "0" has been reached, the desired double total ejection
is carried out after the next partial ejection.

Note:
After entering the password, the partial ejection mode can be
activated/deactivated as described in chapter 3.8.1 "Basic separator settings".
The factory setting is: OFF.

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Filling in SMS mode:

Z 3:SMS Filling
P: 3
A: 2

Fig. 62

Setpoint Actual
Counter Meaning
(P) value (A)
Z3 SMS Filling 3

In single-stage LO separation in WMS/SMS mode, a system check of the SMS

function is carried out by feeding filling water several times. The number of filling
water intervals is set at counter Z3. The factory setting is 3 and should be
changed only for testing purposes.
The number of filling water feeds which are carried out until the system pressure
builds up which is recorded by the SMS sensor and switches back from SMS
operation to WMF operation is entered in entry field (P).
If the pressure is not recorded after the third filling water feed, the ejection
program is started.

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Sensor check:

Z 4:Sensor check
P: 5
A: 0

Fig. 63

Setpoint Actual
Counter Meaning
(P) value (A)
Z4 The number of partial ejection intervals 5
after an automatic sensor check is
defined here.

0.5 % by volume of water

Z 5:0.5-vol-% water
P: 3
A: 0

Fig. 64

Setpoint Actual
Counter Meaning
(P) value (A)
Z5 When the discharge valve is closed, 3
the separation program detects the
pressure in the bypass line provided
timer 47 is started and this is reduced
by one point.
If the value "0" is reached within the
separating interval, an alarm message
"Caution – Water content > 0.5 %" is
generated.

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3.6.6 Adjustment of PID controller

Fig. 65

The "User adjustments" overview is

Fig. 66

The overview for the "Settings" menu

Fig. 67

The individual values can now be

called up one after the other by
PID Control. Manual pressing the down arrow key.
Valve >Manual < Adjusting the PID controller:
F2 key Valve closed • Open or close the controller using
F3 key Valve open the F2/F3 keys.
• Go to the next value using the arrow
keys.
Fig. 68 • Press the Edit key. The LED in the
Edit key goes on.
• Enter the new value using the
function keys.
• Press the Enter key. The new value
is accepted.
• Go to the next value using the arrow
keys.

Note:
An explanation on the adjustment of the PID controller can be found on the
following pages.

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PID Control. Manual

Valve >Manual <
F2 key Valve closed
F3 key Valve open

Fig. 69

Display Meaning
PID Controller Pressing the "PID controller" key allows selecting
Manual/Auto between the two PID controller operating modes.
• Manual: Opening/closing of the valve is by the
function keys F2/F3.
• Auto: Automatic valve actuation by the PID controller,
using the pre-set parameters.
Valve Status display of PID controller:
Manual/Auto
• Manual: PID controller in manual operation
• Auto: PID controller in automatic operation
F2/F3 keys F2: With manual PID controller operation, the valve is
Valve closed/open closed.
F3: With manual PID controller operation, the valve is
opened.

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Setpoint 90°C
Act. value 89°C
Kp (P part) 1.5
Tn (I part) 5 sec

Fig. 70

Actual
Display Meaning Setpoint
value
Setpoint Entry of desired product
temperature
Actual value Display of current product
temperature
Kp (P part) Entry of control response 0.08
(proportional value)
Tn (I part) Entry of response time (integral 100 s
value)

Note:
The control response (Kp) and the response time (Tn) have been pre-set at the
factory on the basis of experience and do not need to be modified under normal
conditions.

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Adaptation of measuring transducer:

AI 0.3 PID controll.

1X2. 76/77 89°C
Final value: 120°C

Fig. 71

Actual
Display Meaning Setpoint
value
AI 0.3 PID Current input value of PID
controller 1X2. controller
76/77
Final value Setting of final value 120 °C
(248 °F)

Special cases require an adaptation to the measuring transducer used locally if

the 4-20 mA signal is provided externally.
To do this, simply overwrite the existing default value with the desired value.

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3.6.7 Display of separator data / service addresses

Fig. 72

The "User adjustments" overview is

Fig. 73

The overview for the "Info" menu is

displayed.
ALARM_C • Call up the menu for "Display of
| SERVICE separator data / service addresses"
| INFO using the F2 key.
| |

Fig. 74

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The individual values can now be

called up one after the other by
Serial number Sepa. pressing the down arrow key.
-> 1234-567 <- The serial number and the start-up
Start-up date date can be entered.
-> 17.11.2002 <- • Go to the value using the arrow
keys.
• Press the Edit key. The LED in the
Fig. 75 Edit key goes on.
• Enter the new value using the
function keys.
• Press the Enter key. The new value
is accepted.
• Go to the next value using the arrow
keys or scroll through the individual
menus.

Display Meaning
Separator serial number Entry of serial number of controlled separator.
Start-up date Entry of start-up date.
Prog Display of current software number.
Version Display of current software version.
Control unit part no. Part no. of control unit
Date Display of current date.
Time Display of current time.
Service Sep. The operating hours have to be aligned with
Operating hours the mechanical operating hour counter in the
motor control system. To do so, the value can
be corrected. The operating hour counter
counts a maximum of 32767 hours before it
restarts at 0.
Service addresses All service addresses can be called up one
after the other here.

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3.6.8 Display of counters for operating and alarm messages

Carry out the following steps to display
the counters for operating and alarm
USER messages.
| ADJUSTM. • Call up the "User adjustments"
| | SERVICE menu using the F1 key.
| | | D10

Fig. 76

The "User adjustments" overview is

Fig. 77

The overview for the "Info" menu is

displayed.
ALARM_C • Call up the menu for "Display of
| SERVICE counters for operating and alarm
| INFO messages" using the F1 key.
| |

Fig. 78

• The individual values can now be

called up one after the other by
Sep. Operating data pressing the down arrow key.
OP hour: 77h
Ejection 44
Starts 37

Fig. 79

Display Meaning
OP hour Number of operating hours of separator. This number
of hours is the basis for the required service measures
(see separator instruction manual).
Ejection The number of completed total ejections is shown in
this line.
Starts The number of completed start-ups of the separator is
shown in this line.

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Display Meaning
WMS / periodic Number of WMS functions per separation unit. On the
UNITROL separator with activated water content
monitoring system, the number of water discharges for
each set separating time is recorded. For a manual
separation stop, the displayed value is set to 0.
WMS / tot. Number of WMS functions. On the UNITROL
separator with activated water content monitoring
system, the number of water discharges is recorded
continuously. The displayed value cannot be reset.
SMS / per. Number of SMS functions per separation unit. On the
UNITROL separator with activated sludge monitoring
system, the number of ejections for each set
separating time is recorded using the SMS. For a
manual separation stop, the displayed value is set to
0.
SMS / tot. Number of SMS functions. On the UNITROL separator
with activated sludge monitoring system, the number
of ejections is recorded continuously using the SMS.
The displayed value cannot be reset.
Water discharge time The opening time of the water discharge valve is
total recorded continuously and in terms of time. The value
cannot be reset.
Water discharge time The opening time of the water discharge valve is
periodic recorded in terms of time for each separation interval
and reset upon the next ejection.
PTC alarms This alarm is recorded when there is a shutdown
initiated by the PTC sensors integrated into the
separator motor windings.
PAL alarms This alarm is recorded when there is a separation
process shutdown initiated by the minimum pressure
controller installed in the product discharge.
PAH alarms This alarm is recorded when there is a separation
process shutdown initiated by the maximum pressure
controller installed in the product discharge (option,
not standard equipment).
FSH alarms This alarm is recorded when there is a separation
process shutdown initiated by the maximum level
switch installed in the water discharge (option, not
standard equipment).

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Display Meaning
LSHH alarm LSHH sludge tank. This alarm is recorded when there
is a separation process shutdown initiated by the level
limit switch "high/high" installed in the sludge tank.
TSL alarm TSL product feed temperature. This alarm is recorded
when there is a separation process shutdown initiated
by the PT 100 temperature sensor installed in the feed
line.
TSH alarm TSH product feed temperature. This alarm is recorded
when there is a separation process shutdown initiated
by the PT 100 temperature sensor installed in the feed
line.
ISL alarm Ejection monitoring. This alarm is recorded when the
ejection program is interrupted due to a response by
the current monitoring.
SLUDGE PUMP The tripping of the sludge pump circuit breaker is
ALARM recorded.
FEED PUMP The tripping of the feed pump circuit breaker is
ALARM recorded.
Black-out The number of power failures during the running
separation program is recorded.
Sludge pump: The switch-on intervals of the sludge pump in the last
Counter last 24 h 24 hours are recorded.
Water discharge The number of continuous water discharge intervals
alarm which were greater than T23 are recorded.
Vibro-1-Alarm Vibration stage 1 alarm. This alarm is recorded when
the separation process is shut down due to the
vibration switch installed on the separator and
available as an option.
Vibro-2-Alarm Vibration stage 2 alarm. This alarm is recorded when
the separator is shut down due to the vibration switch
installed on the separator and available as an option.

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3.7 Service adjustments

Selection of the "Service adjustments"
menu (accessible only after entering a
USER password) is from the main overview
| ADJUSTM. (see also chapter 3.4 "Menu
| | SERVICE overview").
| | | D10 • Press the F3 key, the password
entry is called up.
• Enter the password.
Fig. 80 • Press the down arrow key again.
The "Adjustments" overview is
displayed.
The following menus are called up
from the "Service adjustments"
Inputs overview:
| Outputs • F1 key: Display of digital inputs
| | Mainten • F2 key: Display of digital outputs
| | | Volume • F3 key: Setting the time of
maintenance interval
• F4 key: Entry of specific separator
Fig. 81 data

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3.7.1 Display of digital inputs

Fig. 82

• The individual values can now be

called up one after the other by
DI0.0:Separator On pressing the down arrow key.
>0< 1X2.01/02
DI0.1:Sep. fail
>0< 1X2.03/04

Fig. 83

Input Function Terminal Status

DI 0.0 Separator in operation 1X2. 01/02 0
DI 0.1 Separator fault 1X2. 03/04 0
DI 0.2 PSL product discharge 1X2. 05/06 0
DI 0.3 PSH product discharge 1X2. 07/08 0
DI 0.4 FSH water discharge 1X2. 09/10 0
DI 0.5 WMS-UNITROL 1X2. 11/12 0
DI 0.6 SMS-UNITROL 1X2. 13/14 0
DI 0.7 LSHH sludge tank 1X2. 15/16 0
DI 1.0 Feed pump "operation" 2K2 19/20 0
DI 1.1 Feed pump "failure" 2Q2 21/22 0
DI 1.2 Sludge pump "operation" 5K1 23/24 0
DI 1.3 Sludge pump "failure" 5Q1 25/26 0
DI 1.4 LSH sludge tank for pump start 1X2. 27/28 0
DI 1.5 LSL sludge tank for pump stop 1X2. 29/30 0
DI 1.6 Vibration level 1 1X2. 31/32 0
DI 1.7 Vibration level 2 1X2. 33/34 0
DI 2.0 Emergency stop 1X2 0

Status definition:
• 0 = Input signal 24 VDC not available
• 1 = Input signal 24 VDC available

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3.7.2 Display of digital outputs

Fig. 84

• The individual values can now be

called up one after the other by
DO0.0:Productvalve pressing the down arrow key.
>0< 1X2.41/42
DO0.1:Watervalve
>0< 1X2.43/44

Fig. 85

Output Function Terminal Status

DO 0.0 Product valve 1X2. 41/42 0
DO 0.1 Water valve 1X2. 43/44 0
DO 0.2 Control water valve 1X2. 45/46 0
DO 0.3 Steam valve 1X2. 47/48 0
DO 0.4 Circulation valve 1X2. 49/50 0
DO 0.5 Water discharge valve 1X2. 51/52 0
DO 0.6 Lamp test (option) 0
DO 0.7 Common alarm 1K11/1X2. 67/68 0
DO 1.0 Separator 1K12 0
DO 1.1 Feed pump 1K13 0
DO 1.2 Sludge pump 1K14 0
DO 1.3 TSL (Option) 1K15 0
DO 1.4 TSH (Option) 1K16 0
DO 1.5 Brake (option) 1K17 0
DO 1.6 PID open (option) 1K18 0
DO 1.7 PID close (option) 1K19 0

Status definition:
• 0 = Input signal 24 VDC not available
• 1 = Input signal 24 VDC available

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3.7.3 Setting the time of maintenance interval

Fig. 86

• Press the Edit key. The LED in the

Edit key goes on.
Maintenance-Interva. • Enter the new value using the
Adjust. operating h function keys.
Set: 4000 h • Press the Enter key. The new value
Actual: 2145 h is accepted.

Fig. 87

The factory setting for "Set" is a maintenance interval of 4000 hours as specified
in the separator instruction manual. Under "Actual", the operating hours of the
separator are counted.
When the pre-set number of operating hours is reached, a common alarm is
activated and a corresponding warning appears in the display. A common alarm
does not interrupt the separating program and must be acknowledged using the
Enter key.

Note:
Please take the maintenance interval setting from the instruction manual of the
separator used.

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3.7.4 Entry of specific separator data

Fig. 88

• Press the Edit key. The LED in the

Edit key goes on.
Volume to SMS • Enter the new value using the
Liter function keys.
Volume Displacement • Press the Enter key. The new value
Liter is accepted.

Fig. 89

Note:
An explanation regarding the entries of specific separator data can be found on
the following pages.

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Volumes for SMS registration, displacement and filling:

Volume to SMS
Liter
Volume Displacement
Liter

Fig. 90

Actual
Display Meaning Setpoint
value
Volume to SMS Depending on separator size,
the value for the function
"Volume in liters up to SMS
registration" is entered here
according to the table in chapter
"Commissioning settings" in the
instruction manual of the
separator.
Volume Depending on separator size,
Displacement the value for the function
"Volume in liters for
displacement" is entered here
according to the table in chapter
"Commissioning settings" in the
instruction manual of the
separator.

Volume Fillingw.
Liter

Fig. 91

Actual
Display Meaning Setpoint
value
Volume Depending on separator size,
Fillingwater the value for the function
"Volume in liters for filling" is
entered here according to the
table in chapter "Commissioning
settings" in the instruction
manual of the separator.

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Sensor check:

Water impulses for

Sensor check
T60: Start impuls
P: sec A: sec

Fig. 92

Setpoint Actual
Display Meaning
(P) value (A)
Start impuls In case of manual start or if 10.0 s
counter 4 "sensor check" has
expired, the filling and
displacement water valve will be
opened for 10 seconds.

T61: Sensor pause

P: sec A: sec
T62: Sensor impuls
P: sec A: sec

Fig. 93

Setpoint Actual
Display Meaning
(P) value (A)
Sensor pause After filling by timer T60, there is 3s
a 3-second pause by means of
timer T61.
Sensor impuls After expiry of the pause period 1s
of timer T61, water is again fed
in by means of timer T62 during
one second, using the filling and
displacement water valve.

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3.8 Timer and separator adjustments

Selection of the "Timer and separator
adjustments" menu (accessible only
USER after entering a password) is from the
| ADJUSTM. main overview (see also chapter 3.4
| | SERVICE "Menu overview").
| | | D10 • Press the F2 key. The password
input screen is called up.
• Enter the password.
Fig. 94 • Press the down arrow key again.
The "Timer and separator
adjustments" overview is called up.

The following menus are called up

Fig. 95

3.8.1 Basic separator settings

The basic separator settings are factory settings.
Selection of basic separator settings:
• From the "Timer and separator
SEP adjustments" overview, press the F1
| TIMER 1 key.
| | TIMER 2
| | |

Fig. 96

• The individual basic settings can be

called up one after the other by
PSL Monitoring pressing the down arrow key.
Button F1: > Off < • For adjustment, a F key is assigned
SMS alarm in idle to the function to be adjusted.
Button F2: > OFF < – The status changes each time the
F key is pressed.

Fig. 97

Note:
An explanation regarding the individual separator settings can be found on the
following pages.

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PSL Monitoring
Button F1: > Off <
SMS alarm in idle
Button F2: > OFF <

Fig. 98

Lines 1 + 2:
Function Statuses
PSL Monitoring • F1 = ON/OFF

Press the F1 key to activate function monitoring of the pressure control device in
the product discharge. With function monitoring activated, status 0 of the
pressure control device in the ejection program is scanned. A faulty permanent
signal due to a defective pressure control device is thus excluded.
Should this fault occur, a corresponding message appears in the display and the
alarm system is activated.
Pressing the F1 key again deactivates function monitoring.

Lines 3 +4:
Function Statuses
SMS idle alarm in single-stage WMS/SMS-36 or • F2 = ON/OFF
WMS/SMS-96 operation.

Press the F2 key to activate the SMS idle alarm monitoring of the pressure
control device in the bypass line. With the SMS idle alarm monitoring activated,
the ejection program is activated in idle mode by status 1 of the pressure control
device.
Should this system-dependent ejection occur, a corresponding message
appears in the display and the alarm system is activated.
Pressing the F2 key again deactivates the SMS idle alarm monitoring.

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[Link] by idle oper

Button F1: > Off <
Separator cooling
Button F2: > OFF <

Fig. 99

Lines 1 + 2:
Function Statuses
Separator shut-down in idle after expiry of a delay • F1 = ON/OFF
period.

Press the F1 key to activate automatic shutdown of the separator in idle mode.
If the display reads ON, the separator is shut down following an ejection if after
expiry of timer 39, separation (process) is not activated again.
The idle mode becomes active after an alarm with feed valve closing or after
start-up. Should this status occur, a corresponding message appears in the
display and the alarm system is activated.
Pressing the F1 key again deactivates the function of automatic separator
shutdown in idle mode.

Lines 3 +4:
Function Statuses
Separator – Cooling program • F2 = ON/OFF

In case of unmanned separator operation in land-based instrallations, we

recommend activating the cooling program in order to avoid overheating of
materials and seals in idle operation. Press the F2 key to activate the cooling
program during idle operation of the separator.
If the separator is in idle operation, the displacement and filling water valve is
opened, depending on the separator size, after expiry of the set 600 sec of timer
30 (pause cooling water) via timer 31 (cooling water feed) and the separator is
fed with cooling water. In idle operation, this process is repeated cyclically.
Pressing the F2 key again deactivates the separator cooling program.

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WMS 01:ButtonF1>Off<
SMS 36:ButtonF2>Off<
SMS 96:ButtonF3>Off<
[Link]:ButtonF1>Off<

Fig. 100

Line 1:
Function Statuses
UNITROL separator (01) with water content • F1 = ON/OFF
monitoring system (WMS)

Press the F1 key to activate the water content monitoring system of the
separator. During the separation program, a conductivity meter (CS) in the
bypass line monitors the liquid concentration and discharges registered water
directly by opening the water discharge valve. The water discharge is registered
and is shown in the display. In two-stage HFO separation operation, the
separator of stage 1 is operated with an activated WMS system.
Pressing the F1 key again deactivates the water content monitoring system.

Line 2:
Function Statuses
UNITROL separator (36) with sludge monitoring • F2 = ON/OFF
system for HFO

Press the F2 key to activate the sludge monitoring system of the separator.
During the separation program, a pressure control device (PSL) in the bypass
line monitors the pressure inside the system. In case of a pressure drop due to
registered sludge or water concentrations, an ejection is initiated after expiry of
a 10-second delay period from timer 27. SMS-dependent ejections are
registered. In two-stage HFO separation operation, the separator of stage 2 is
operated with an activated SMS system.
Pressing the F2 key again deactivates the sludge monitoring system.

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Line 3:
Function Statuses
UNITROL separator (96) with sludge monitoring • F3 = ON/OFF
system for LO

Press the F3 key to activate the sludge monitoring system of the separator.
During the separation program, a pressure control device (PSL) in the bypass
line monitors the pressure inside the system. In case of a pressure drop due to
registered sludge or water concentrations, an ejection is initiated after expiry of
a 10-second delay period from timer 27. SMS-dependent ejections are
registered.
Pressing the F3 key again deactivates the sludge monitoring system.
Note:
If a separator with WMS-/SMS-36 for HFO or WMS-/SMS-96 for LO is to be
used in single operation, both keys of the desired selections must be activated
(see also the separate document "Timer and parameter lists").

Line 4:
Function Statuses
Sensor check • F4 = ON/OFF

With UNITROL separators with activated WMS or SMS sensors, the F4 key
allows checking the proper function of the CS sensor and the pressure control
device in the bypass line.
When starting the ejection program manually or after expiry of the pre-selection
counter C06, the signalling capability of WMS and SMS sensors is tested by
feeding water. The separation process is only released when proper function is
ensured. Corresponding alarms are released in case of faulty functions. The
testing time for the WMS and SMS sensors can be pre-set using timer 3.
Pressing the F4 key again deactivates the sensor check.

Note:
Activating the sensor check also releases the calculation of the automatic water
feed for displacement and filling.
To do this, enter the bowl volumes, depending on separator size, for the
functions "Volume in liters up to SMS registration", "Volume in liters for
displacement" and "Volume in liters for filling" according to the table specified in
chapter "Commissioning settings" in the separator instruction manual, chapter
"Service".

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Transducer:
Button F1: >1:50<
Bowl monitoring:
Button F2: > Off <

Fig. 101

Line 1:
Function Statuses
Separator current transformer for local motor • F1 = 10/1; 25/1; 50/1;
starters 100/1

Due to the differing separator motor power ratings, the current transformer ratio
can be adapted if external motor starters are used so the control unit display will
show the correct motor current of the separator.
Pressing the F1 key several times allows selecting the desired ratio.

Line 2:
Function Statuses
Bowl monitoring • F2 = ON/OFF

Press the F2 key to activate the bowl monitoring of the separator.

The bowl monitoring monitors the cyclic closing water pulse for bowl hydraulics,
i.e. if the closing water quantity is too large, the drum is opened which in turn
causes a current rise.
Bowl monitoring is controlled as follows:
• 3 seconds before feeding the closing water, the current operating current is
measured and stored.
• 3 seconds after feeding the closing water, the operating current is measured
again and compared with the previous value.
• When the offset value deviates, a corresponding alarm message is
generated.
• The separation process is not interrupted.
Pressing the F2 key again deactivates bowl monitoring.

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Separator Typ:
Button F1: >OSD-18<
Part. Ejection:
Button F2: > Off <

Fig. 102

Line 1:
Function Statuses
Selection of separator type • F1 = OSD-6; OSD-18;
OSD-35; OSD-60,
OSD-80

As a factory setting, the D10 control unit is set to the separator type used and all
corresponding timer values are loaded automatically. If a new assignment is
required for service reasons, pressing the F1 key several times allows selecting
the desired separator type.
When exchanging the control unit, the separators of the preceding series OSC,
OSB and OSA may be selected as well.
Press the F1 key until the separator type in the display changes. The activation
is delayed by 3 seconds in order to avoid unintended type changes.

Line 2:
Function Statuses
Activation of partial ejection program • F2 = ON/OFF

Press the F2 key to activate the partial ejection program.

With OSD separators, partial ejections are also possible if the control water
system meets the requirements. Time- and SMS-dependent ejections are
carried out as partial ejections if the current value of the partial ejection counter
Z2 has not countered down to zero.
Ejections initiated manually using the "Process Stop/Start" keys as well as the
zero status of counter Z2 are always carried out as total ejections.
Pressing the F2 key again deactivates the partial ejection program.
See also the chapter "Partial ejection" in the separator instruction manual.

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CU Sludge pump
Button F1: > Off <
Free:
Button F2: > Off <

Fig. 103

Line 1:
Function Statuses
Control of sludge pump with Compact Units (CU) • F1 = ON/OFF

With Compact Units, the sludge tank is normally equipped with one LSHH level
switch only for reasons of space. The LSH level switch for switching on and the
LSL level switch for switching off the sludge pump are dropped.
Pressing the F1 key selects the CU function and the sludge pump is started
automatically upon ejection. In addition, the sludge pump is switched off by
timer 40 according to the sludge tank volume and the pump capacity. The timers
have to be adapted locally if required. In separation operation, there is a cyclic
pause and pulse operation which can be modified using T41 (pause) and T40
(operation).
The level signals for LSH and LSL are not required by the software now and
suppressed by the program.
Pressing the F1 key again deactivates the CU function selection.

Line 2:
Function Statuses
Free, option for possible special functions • F2 = ON/OFF

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3.8.2 Setting the timers

For a detailed description of the timers, please refer to the separate document
"Timer and parameter lists".
Selection of basic separator settings:
• From the "Timer and separator
SEP adjustments" overview, press the F2
| TIMER 1 or F3 key.
| | TIMER 2
| | |

Fig. 104

With the exception of the free timers

described in the chapter "User timers",
Timer-List 1 access to the timers is password-
controlled.
T00: Part. ejection • The first timer menu is called up.
P: 1.1sec A: 0sec. • The other timer menus can now be
scrolled and/or set one after the
other by pressing the arrow keys.
Fig. 105

A fixed unit is assigned to every timer. If decimal places are displayed, the time
can be entered with the associated degree of precision. The initial setpoints
depend on the selected separator type.
A letter appears ahead of the respective value in the displayed timer. These
letters have the following meaning:
• P: Setpoint (preset)
• A: Actual value

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3.9 D10 system menu

Selection of the D10 system menu is
from the main overview (see also
USER chapter 3.4 "Menu overview").
| ADJUSTM. • Press the F4 key. The D10 system
| | SERVICE menu overview is called up.
| | | D10

Fig. 106

The following menus are called up

from the D10 system menu:
DATE/TIME • F1 key: Setting of date and time
| ALARMS • F2 key: Fault message history
| | LANGUAGE • F3 key: Language selection
| | |CONTR. • F4 key: Contrast adjustment

Fig. 107

3.9.1 Setting of date / time

Selecting the menu from the D10
system menu overview:
Change date/time • Press the F1 key. The date/time are
26. 4. 3 [Link] displayed.

Setting the date/time:

• Press the left/right arrow keys. Move
the cursor to the desired value.
Fig. 108 • Press the Edit key. The LED in the
Edit key goes on.
• Set the value using the function
keys.
• Press the Enter key. The new
selection is accepted.

Note: The selection can be undone by

pressing the Esc key. The existing
setting remains intact and the program
returns to the preceding menu.

Display Meaning
Date/time The date and the associated time are necessary to
provide the fault message with the correct time
stamp. The date format is the same for all languages.
A leading “0” is not displayed: In the example above,
the year 03 is displayed as 3.
When the D10 control unit is switched off, the set
date remains saved for about 6 weeks.

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3.9.2 Display of the fault message buffer

The D10 control unit has a fault message buffer into which the fault messages
are written. A new entry is created in the fault message buffer whenever a fault
status change takes place (fault come/gone/acknowledged).
A maximum of 256 entries can be stored. If the fault message buffer cannot
accept any new fault messages, the oldest entries are automatically deleted.

Note:
For a detailed description of the fault messages, please refer to the separate
document "Faults, troubleshooting".

Example:
Selecting the menu from the D10
system menu overview:
<Failure> I 001/015 • Press the F2 key. The fault
#009 MOTOR PROTEC. message buffer display appears.
at 10.12.03 [Link] – The fault messages are stored in
the fault message buffer in the
order in which they have arisen.
• Press the arrow up/down keys.
Fig. 109 Navigate through the fault message
buffer to view all messages.
• Press the Esc key. The fault
message buffer is quit.

Explanation of the display example:

Display Meaning
<Failure> A fault message is displayed.
I Status of the fault message:
• I = fault message has come
• A = fault message has been acknowledged
• O = fault message has gone
001/015 The fault message shown is in position 1 (most
recent message). There are 15 fault messages in the
fault message buffer. 001 to 256 fault messages are
possible.
#009 MOTOR Fault number and fault message in plain text.
PROTEC.
at 10.12.03 [Link] Date and time at the time of the status change
(come / acknowledged / gone) of the fault message.

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Westfalia Separator Mineraloil Systems GmbH 93

3.9.3 Language selection

Selecting the menu from the D10
system menu overview:
Language selection: • Press the F3 key. The language
Current: GER currently selected is displayed.
New: ENG

Fig. 110

Depending on the program version, 5 languages are available for language

selection.
Program version Languages Abbreviation
D10-0A1-V1.20* German GER
English ENG
French FRA
Italian ITA
Spanish ESP

The program version may change due to technical changes.

To select a new language:

• Press up/down arrow key. The
$ 002 transfer languages can be selected one after
>Parameterization < the other.
>running < • Press the Enter key. The new
selection is accepted, the program
restarts.

Fig. 111 Note: The selection can be undone by

pressing the Esc key. The existing
setting remains intact and the program
returns to the preceding menu.

For firmware reasons some system outputs are only available in the languages
of program version D10-0A1-V1.20*. If other languages are selected, the
program is displayed in English.
Note:
Following a language selection, the new language is transferred from the Micro
Memory Card (MMC) which takes approx. 3 minutes. During this period, no data
is shown on the display, the selection is accepted only after pressing the Enter
key and the program re-starts.

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94 Westfalia Separator Mineraloil Systems GmbH

3.9.4 Contrast adjustment

Selecting the menu from the D10
system menu overview:
Display Contrast: • Press the F4 key. The contrast
currently set is displayed.
Contrast: 6 • Press arrow up/down key. Adjust a
contrast value between 0 and 15.
– 0 = smallest contrast
– 15 = largest contrast
Fig. 112 • Press the Enter key. The new
selection is accepted.

Note: The selection can be undone by

pressing the Esc key. The existing
setting remains intact and the program
returns to the preceding menu.

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Westfalia Separator Mineraloil Systems GmbH 95

3.10 Program settings

You will find important information concerning the program settings in the
following chapters.

3.10.1 Setting the separation time

Precise setting of the separation time (period in between ejections) with time-
dependent automatic program run is only possible if the flow quantity and the
sludge content of the product fed into the separator remain constant. If this is
not the case, the setting may need to be corrected during operation.
The separating time depends on
• the pre-selected operating mode (partial or total ejection mode),
• the sludge content of the product to be centrifuged,
• the sludge consistency,
• the usable sludge volume inside the bowl,
• the throughput capacity of the separator.
When conditions are constant, the separating time can be calculated.
The following times have stood the test in practice:

Product Total ejection Partial ejection

HFO 2 h up to 4 h max. 1h
MDO 6h 3h
LO mild 6 h up to 8 h max. 3h
LO HD 2 h up to 4 h max. 1h

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96 Westfalia Separator Mineraloil Systems GmbH

3.10.2 Calculation of separating time

Example for calculating the separation time:

Given: Sludge content (1) p = 0.05 %

Sludge space volume V = 1.5 l

Sludge space at 75% utilization V' = 1.13 l

Throughput (1) Vo = 2000 l/h

Wanted: Separating time t = ? min

The separation time to be adjusted is calculated as follows:

V’ 1.13
t = ——— • 60 • 100 = —————— • 6 000 = 67.8 min = 1.1 h
V° • p 2000 • 0.05

(1)
Sludge content and throughput must be determined locally or be taken from the
job specification.

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3.11 Changing the Micro Memory Card (MMC)

The control program and all setting/adjustment data are stored on the
removable Micro Memory Card (MMC). If required, these data can be
downloaded, e.g. when the Micro Memory Card (MMC) is inserted into a new
D10 control unit.

The D10 control unit cannot be used without a Micro Memory Card (MMC) or
with a defective card. In this case the message “CPU is in Stop” will be
displayed.

Fig. 113

1 “X7 MMC” slot

2 Micro Memory Card (MMC)

Make sure that the power supply unit is switched off prior to changing the Micro
Memory Card (MMC).

When a new Micro Memory Card (MMC) has been connected, the D10 is in the
STOP mode after it is switched on for the first time. Switch the voltage supply off
and on again. After that the D10 is in the RUN mode.

The Micro Memory Card (MMC) must not be read out using commercially
available card readers. The program may be destroyed.
Only the D10 control unit purchased from Westfalia Separator Mineraloil
Systems GmbH can read the program content on the MMC and proper
operation can be guaranteed.

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98 Westfalia Separator Mineraloil Systems GmbH

3.12 Memory reset

3.12.1 Connecting the jumper

Only qualified personnel is authorised to open the control cabinet.

Normally, the operating modes RUN, STOP and MRES cannot be changed
using the operating mode selector switch of the D10 control unit. If, however,
this is required for some reason, e.g. to reset the memory, a jumper has to be
connected between terminals AT1 and AT2 of the power supply connector in
order to activate the authorization.
Whenever the operating mode selector switch is pressed, the status of the D10
control unit is changed.

Fig. 114

1 Power supply connector X1

2 Jumper between AT1 and AT2

The RUN key has to be pressed for at least 500 ms to trigger the status change
and to cause the key LED to light up. The key LEDs do not indicate the
operating status of the D10 control unit, but the position of the operating mode
keys.

To continue using the unit the jumper has to be removed again.

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3.12.2 CPU reset

Under certain circumstances it might be necessary to reset the CPU of the D10
control unit.

Resetting the CPU means that the CPU is reinitialised. The program currently
stored in the RAM memory and all data will be overwritten by the content of the
Micro Memory Card (MMC).

Fig. 115

• Select the operating mode “STOP” by pressing the DOWN key (2):
– the LED “S” lights up,
– the LED “STOP” lights up.
• Select the operating mode MRES by simultaneously pressing the UP key (1)
and the DOWN key (2):
– The LED “M” lights up.
• Keep the keys pressed until the status LED “STOP” lights up a second time
and remains on (after about 3 seconds).
• Then release the keys.
• You have to press both keys again within 3 seconds.
• When the LED “STOP” flashes rapidly (at about 2 Hz), you can release the
keys.
When the CPU has been reset, the LED “STOP” stops to flash and remains
permanently on.
The CPU is now reset and the program is in the STOP state.

Note:
The steps described are only necessary if the user wants to reset the D10
control unit himself. If the D10 control unit automatically requests to be reset,
which is indicated by a slow flashing of the LED “STOP”, it is sufficient to press
the UP key (1) and the DOWN key (2) simultaneously to start the resetting
process.

8555-9001-000/1203
100 Westfalia Separator Mineraloil Systems GmbH

3.13 Basic setting of evaluation relays RM3 + RM4

The conductivity in the sensor circuit is evaluated using the evaluation relays
RM3 or RM4. The basic setting of the evaluation relays is done as described in
the chapters below.

3.13.1 Evaluation relay RM3

1 2

Fig. 116

1 Function: Dropout delay, setting of delay time upon product registration

by the sensor if water was discharged before.
2 R-sector: Setting of maximum measuring range, we recommend
50 kOhm.
3 R-value: Setting of desired sensitivity, the setpoint is 20 kOhm at a
reading of 20.
During commissioning, test the following functions using the water valve
open/close during separation:
– Water registration - display Water discharge
– Product registration - display Feed valve open
4 Green LED: Indicates that the unit is ready for operation.
5 Yellow LED: Indicates water discharge.
6 Time value s: Delay time for switching back from water to product.

Note:
The unit will not work when chemically clean water (distillate) is used.

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Westfalia Separator Mineraloil Systems GmbH 101

3.13.2 Evaluation relay RM4

5 3

Fig. 117

1 t: Dropout delay: setting of delay time upon product registration by the

sensor if water was discharged before.
2 K: Sensitivity setting: A 40% setting refers to the measuring range pre-
selected below of 50 kOhm.
During commissioning, test the following functions using the water valve
open/close during separation:
– Water registration - display Water discharge
– Product registration - display Feed valve open
3 Setting: Ejection or filling, set slide switch to the left to "Ejection".
4 Function/Range: Setting of measuring range: Pre-set to 50x, resulting in
a response range of 40% based on 50 kOhm and a delay time from
water registration to water discharge.
5 Green LED: Indicates that the unit is ready for operation.
6 Yellow LED: Indicates water discharge.

Note:
The unit will not work when chemically clean water (distillate) is used.

8555-9001-000/1203
102 Westfalia Separator Mineraloil Systems GmbH

Note
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8555-9001-000/1203
Westfalia Separator Mineraloil Systems GmbH 103

4 Maintenance

4.1 Avoiding accidents...............................................................................104

4.2 Requirements concerning the service personnel and spare parts ......104
4.3 Removing faults ...................................................................................104

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104 Westfalia Separator Mineraloil Systems GmbH

4.1 Avoiding accidents

Comply with the safety instruction in section 1 for maintenance and care.
The most important safety instructions which especially concern maintenance
and care will now be repeated for reasons of safety.

Prior to performing any maintenance and care

operations:
• Disconnect all electrical systems and equipment
parts from the power supply by actuating the
main switch.
• Secure the unit against accidental reconnection
to power using locking devices.

Fig. 118

4.2 Requirements concerning the service personnel and spare parts

• Use genuine spare parts by Westfalia

Separator only.
The use non-original parts results in:
– safety risks,
– reduced service life and availability,
– increased service needs.
If a safety risk results, the persons not
complying with this information might be subject
Fig. 119 to prosecution under criminal law. Westfalia
Separator shall not assume any liability or give
any warranty in such cases.
• Make sure that only properly qualified personnel is entrusted with maintaining
the unit. This is the case with the service personnel of Westfalia Separator or
personnel trained by Westfalia Separator.
An inadequately maintained/installed machine holds a high safety risk for the
operating personnel.

4.3 Removing faults

To remove faults, please refer to the separate documentation "Faults,
troubleshooting".

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5 Installation and connection

5.1 Installation of control system ...............................................................106

8555-9001-000/1203
106 Westfalia Separator Mineraloil Systems GmbH

5.1 Installation of control system

General installation information

Note:
In particular, the installation instructions by Westfalia Separator shall be
observed.

Mount the control system near the separator either on a wall or on a frame.

If you mount the control system on a wall, make sure that there is a clearance of
about 20 mm between the control unit and the wall.

Seal the installation holes on the rear panel of the control cabinet by under
laying gaskets.
When choosing the place of installation, observe the following criteria:
• If possible, avoid direct sunlight on the display to ensure readability of the
display.
• Overheating of the unit due to external heat sources should be reduced to a
minimum.
• The control system should not be installed in an excessively humid
environment or under wet conditions (see also chapter “Technical data”).

Marine operation
• Mount the control system at a low-vibration place.
• Do not install the control system near hot pipework.
• Arrange the air outlets from the fan and the filter so that sufficient air
circulation is ensured.

Air humidity/moisture
If the control system may get moist, the supply voltage should be applied at all
times to keep the temperature inside the control unit as constant as possible. If
power is supplied via the motor control system, the main switch should remain
activated even if the separator stands still.

8555-9001-000/1203
Westfalia Separator Mineraloil Systems GmbH 107

5.2 Connecting the control system

Note:
In particular, the installation instructions by Westfalia Separator shall be
observed.

Note that certain terminal blocks on the mounting plate are assigned to the
inputs of the outputs of the control unit (see terminal diagrams).

Operating voltages:
Connect the control system only to voltages specified on the nameplate inside
the control cabinet.

The standard rating for the solenoid valves for operating water and control air is
a control voltage of 24 V DC.

The floating contacts of the interface relays carry external voltage, e.g. if they
are integrated in pump controls for interlocking.

The output modules have short-circuit-proof transistor outputs.

Installation instructions:
• Lay the signalling lines separately from lines with higher voltages (e.g. power
cables, motor lines etc.).
• Securely fasten the cable glands for cable entry.

8555-9001-000/1203
108 Westfalia Separator Mineraloil Systems GmbH

5.3 Centralised control via floating contacts

The integration of local separator control systems in customer's central control
systems requires that the communication signals are discussed when placing
the order.
Hardware signals are required to link the D10 control unit with a centralised
control system. The signals are exchanged as follows.

Customer-
provided
D10
control
system
Functions performed Signals

Separator startup Separator start/stop = 1

after approx. 12 minutes,
the separator is ready for operation Standby = 1

Product program ON Product start/stop = 1

Product program OFF Product start/stop = 0

Fault
(Product program OFF)

Up to fault acknowledgement on D10 control Centralised alarm = 1

unit

Separator stop Separator start/stop = 0

Standby = 0

8555-9001-000/1203
Westfalia Separator Mineraloil Systems GmbH 109

5.4 Terminal diagrams

5.4.1 Terminal box on separator

Digital inputs

Fig. 120

Terminal Description
1-2 PSL pressure control device for
product discharge pressure
3-4* PSH pressure control device for
product discharge pressure
5-6* FSH - water discharge
7-8 SMS – Self-control sensor
9-10 WMS – Water discharge sensor

* If the terminal is not used, install a jumper.

Digital outputs

Fig. 121

Terminal Description
11-12 Circulation valve
13-14 Water discharge valve
15-16 Filling and displacement water valve
17-18 Control water valve

8555-9001-000/1203
110 Westfalia Separator Mineraloil Systems GmbH

5.4.2 Analogue inputs

Fig. 122

Terminal Description
77-78/SC PT 100 PI control loop
79-80/SC min./max. temperature monitoring

5.4.3 Floating contacts

Fig. 123

Terminal Description
81-82 Common alarm
83-84 Separator "operation"

8555-9001-000/1203
Westfalia Separator Mineraloil Systems GmbH 111

5.4.4 Digital inputs (terminal strip 1X2 in control cabinet)

Fig. 124

Terminal Description Terminal Description

1-2 Separator motor "ON" 19-20 Feed pump "ON
3-4 Separator motor protection 21-22 Feed pump "Fault"
5-6° PSL - pressure control device for 23-24 Sludge pump "Operation"
product discharge pressure
7-8*° PSH - pressure control device for 25-26 Sludge pump "Fault"
product discharge pressure
9-10*° Water discharge 27-28/30 LSH – Sludge tank level switch
11-12° WMS – Water discharge sensor 29/31-32 LSL – Sludge tank level switch
13-14° SMS – Self-control sensor 33-34* Vibration level 1 / Vibration level 2
35-36*
37-39
15/16/17/ LSHH – Sludge tank level switch 73-74 Limit switch for steam shut-off valve
18*

* If the terminal is not used, install a jumper.

° Input of signals from terminal box (1X10) mounted on separator

8555-9001-000/1203
112 Westfalia Separator Mineraloil Systems GmbH

5.4.5 Digital outputs

Fig. 125

Terminal Description
41-42 Product feed valve
43-44° Filling and displacement water valve
45-46° Control water valve
49-50° Circulation valve
51-52° Water discharge valve
53-54 Sludge pump valve

° Output of signals to terminal box (1X10) mounted on separator

8555-9001-000/1203
Westfalia Separator Mineraloil Systems GmbH 113

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8555-9001-000/1203
Westfalia Separator
Mineraloil Systems GmbH
Take the Best - Separate the Rest

A Company of the mg technologies Group

Westfalia Separator Mineraloil Systems GmbH ● Werner-Habig-Straße 1 ● D-59302 Oelde (F.R. Germany)
Phone: +49 (0) 25 22/77-0 ● Fax: +49 (0) 25 22/77-23 94 ●

[Link] [Link]

Geschäftsbereich
Mechanische Trenntechnik
Westfalia Separator
Mineraloil Systems GmbH

Operating instructions

2
Westfalia Separator Mineraloil Systems GmbH

8555-9001-000/1203

Westfalia Separator Mineraloil Systems GmbH
3
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Geschäftsbereich
Mechanische Trenntechnik
Westfa

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Westfalia Separator Mineraloil Systems GmbH

8555-9001-000/1203

For Your Safety

• Warning indicati

Westfalia Separator Mineraloil Systems GmbH
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8555-9001-000/1203

• Liability for the function of the unit passes to t

6
Westfalia Separator Mineraloil Systems GmbH

8555-9001-000/1203

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1
Safety
9
1.1
Foreword..........................

8
Westfalia Separator Mineraloil Systems GmbH

8555-9001-000/1203
3.7.7
Display of separator data / service ad

Westfalia Separator Mineraloil Systems GmbH
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8555-9001-000/1203

1
Safety

1.1
Foreword.............................

10
Westfalia Separator Mineraloil Systems GmbH

8555-9001-000/1203
1.1
Foreword
The instruction manual is pri

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