Retrofitting a Bauer Motor Gearbox to a KEE BioDisc – Kippen, Stirling
This week we responded to a call-out in Kippen, Stirling, to assess a failed KEE BioDisc sewage treatment plant. The system’s original motor and gearbox had seized completely, leaving the discs motionless and the effluent untreated. Our solution? Strip out the old unit and retrofit a brand new Bauer motor gearbox – restoring proper function to a critical system.
Why Replacing a BioDisc Motor Matters
The rotating discs in a KEE BioDisc rely entirely on the gearbox and motor to maintain biological treatment. Once the motor fails, the disc stops turning and bacteria inside the system begin to die off, leading to poor-quality effluent or total plant failure.
In this case, the original motor had long since reached the end of its life. The bearings were seized, the gearbox was contaminated with water ingress, and the capacitor had blown. We recommended upgrading to a Bauer geared motor – a modern, reliable unit perfect for this kind of retrofit.
Fitting the Bauer Gearbox and Rewiring the Panel
The Bauer motor was mounted directly to the rotor via a new bracket, custom-fitted to match the old KEE disc alignment. With a smooth belt installation and correct belt tensioning, the motor was ready to go – but the control panel wasn’t.
Unlike the original setup, the new Bauer motor includes a capacitor mounted externally to the control panel. As a result, we carried out a complete rewire of the internal control panel to safely accommodate the capacitor and reconfigure motor power delivery. All connections were replaced with high-quality terminals, and we carried out insulation and function testing before powering on.
System Testing and Commissioning
Once installed and wired, we ran full tests to confirm:
- Correct rotation of the BioDisc
- Start-up performance under load
- Full capacitor output and voltage checks
- No belt slippage or vibration on rotation
- Control panel fuses, timers and thermal protection operating correctly
The system is now back online, with smooth rotation and correct effluent flow – ready to serve the household reliably for years to come.
Serving Kippen, Stirling and Rural Central Scotland
Whether it's Bauer retrofits, KEE BioDisc failures, or full control panel rewires, Caledonia Environmental delivers fast, professional service across Kippen, Stirling, and the surrounding rural areas. We specialise in off-grid wastewater systems – so you’re not waiting around on companies who don’t know what a BioDisc even is.
Get the job done right, the first time.
Need Help With Your BioDisc?
If your KEE BioDisc is noisy, seized, tripping power, or just overdue a service – we can help. Whether it's just a belt replacement or a full motor swap and rewire, we’ve got the tools and know-how to keep your system running.
Email: info@caledonia-environmental.co.uk
Phone: 07435 138193
