AMRF4 - HYDAC Imprint HYDAC FILTER SYSTEMS GMBH en(us) Page 2 / 32 MoWa AMRF4 3728735 en-us...

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AMRF4 Automotive MultiRheo Filter 10 bar Installation and Maintenance Instructions English (translation of original instructions) Document No.: 3728735

Transcript of AMRF4 - HYDAC Imprint HYDAC FILTER SYSTEMS GMBH en(us) Page 2 / 32 MoWa AMRF4 3728735 en-us...

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AMRF4

Automotive MultiRheo Filter 10 bar

Installation and Maintenance InstructionsEnglish (translation of original instructions)

Document No.: 3728735

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AMRF4 Imprint

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Imprint

Publisher and responsible for the content:

HYDAC FILTER SYSTEMS GMBH

Postfach 1251

66273 Sulzbach / Saarland

Germany

Telephone: +49 (0)6897 509 01

Telefax: +49 (0)6897 509 846

E-Mail: [email protected]

Homepage: www.hydac.com

Court of Registration: Saarbrücken, HRB 17216

Executive director: Mathias Dieter, Dipl.Kfm. Wolfgang Haering

Documentation Representative

Mr. Günter Harge

c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar

Telephone: ++49 (0)6897 509 1511

Telefax: ++49 (0)6897 509 1394

E-Mail: [email protected]

© HYDAC FILTER SYSTEMS GMBH

All rights reserved. No part of this work may be reproduced in any form (print, photocopy or by other means) or processed, duplicated or distributed using electronic systems without the written consent of the publisher. These documents have been created and inspected with the greatest care. However, errors cannot be ruled out completely.

All details are subject to technical modifications. Technical specifications are subject to change without notice.

The trademarks of other companies are exclusively used for the products of those companies.

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AMRF4 Content

Content

Imprint .......................................................................................................................2

Documentation Representative...............................................................................2

Content......................................................................................................................3

Preface ......................................................................................................................5

Customer Service ...................................................................................................6 Modifications to the Product ...................................................................................6 Warranty .................................................................................................................6 Using the documentation ........................................................................................7

Safety information and instructions .......................................................................8

Obligations and liability ...........................................................................................8 Explanation of Symbols and Warnings, etc. ...........................................................9 Proper/Designated Use ..........................................................................................9 Improper use or use deviating from intended use ..................................................9 Training and Instruction of Personnel ...................................................................10 Dangers by pressure in the hydraulic system.......................................................11 AMRF modification ...............................................................................................11

Unpacking AMRF....................................................................................................11

Storing the AMRF ...................................................................................................11

Checking the scope of delivery.............................................................................12

Technical Description ............................................................................................13

Restrictions pertaining to use ...............................................................................13

Calculating the pressure differential of the filter housing / filter element....................................................................................................................14

Housing : Pressure loss curve, housing..........................................................14 p

Filter element- : pressure loss calculation, filter element .................................14 p

R (Resistance) Factors .........................................................................................15 Filter material ....................................................................................................15 Maximum differential pressure at the filter element ..........................................15 Filter element FlexMicron P (Premium).............................................................15 Filter element FlexMicron S (Standard) ............................................................16 Filter element FlexMicron E (Economy) ............................................................16

AMRF components.................................................................................................17

Dimensions .............................................................................................................18

Hydraulic diagram ..................................................................................................19

Setting up / fastening AMRF..................................................................................20

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AMRF4 Content

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Hydraulic connection of the AMRF.......................................................................20

Notes on pipes and hoses ....................................................................................21

Starting up the AMRF.............................................................................................22

Performing maintenance .......................................................................................22

Replacing the filter elements ................................................................................23

Spare parts..............................................................................................................26

Disposing of the AMRF..........................................................................................28

Customer Service...................................................................................................28

Technical data ........................................................................................................28

Model Code .............................................................................................................29

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AMRF4 Preface

Preface

For you, as the owner of a product manufactured by us, we have produced this manual, comprising the most important instructions for its operation and maintenance.

It is intended to help you become acquainted with the ins and outs of the product and use it properly.

You should keep it in the vicinity of the product so it is always at your fingertips.

Sometimes the information contained in this documentation cannot always keep up with changes made to the product as we attach considerable importance to keeping our products cutting-edge.Consequently, there might be deviations in technical details, illustrations and dimensions.

If you discover errors while reading the documentation or have suggestions or other useful information, please don’t hesitate to contact us:

HYDAC FILTER SYSTEMS GMBHTechnische DokumentationPostfach 12 5166273 Sulzbach / Saar

Germany

We look forward to receiving your input.

“Putting experience into practice”

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AMRF4 Preface

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Customer Service If you have any questions, suggestions, or encounter any problems of a technical nature, please don't hesitate to contact us. When contacting us, please always include the model/type designation and article no. of the product:

Fax: ++49 (0) 6897 / 509 - 846

E-Mail: [email protected]

Modifications to the Product We would like to point out that changes to the product (e.g. purchasing options, etc.) may result in the information in the operating instructions no longer being completely accurate or sufficient.

When making modifications or performing repair work to components affecting the safety of the product, the product may not be put back into operation until it has been examined and released by a HYDAC representative.

Please notify us immediately of any modifications made to the product whether by you or a third party.

Warranty For the warranty provided by us, please refer to the General Terms of Sale and Delivery of HYDAC Filter Systems GmbH.

You will find these under www.hydac.com -> General terms and conditions.

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AMRF4 Preface

Using the documentation

Note that the method described for locating specific information does not release you from your responsibility of carefully reading these instructions prior to starting the unit up for the first time and at regular intervals in the future.

WHAT do I want to know?

I determine which topic I am looking for.

WHERE can I find the information I’m looking for?

The document has a table of contents at the beginning. I select the chapter I'm looking for and the corresponding page number.

deHYDAC Filtertechnik GmbHBeWa 123456a de

Seite x

Produkt / Kapitel

200x-xx-xx

Chapter

Page number

Edition date

Document language Documentation No.with Index /

File name

The documentation number with its index enables you to order another copy of the operating and maintenance instructions. The index is incremented every time the manual is revised or changed.

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AMRF4 Safety information and instructions

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Safety information and instructions

These installation and maintenance instructions contain the key instructions for properly and safely operating the AMRF.

Obligations and liability

The basic prerequisite for the safe and proper handling and operation of the AMRF is knowledge of the safety precautions and regulations.

These operating instructions in general, and the safety precautions in particular, are to be adhered by all those who work with the AMRF.

Adherence is to be maintained to pertinent accident prevention regulations applicable at the site where the product is used.

The safety guidelines listed here are restricted to use of the AMRF.

The AMRF has been designed and constructed in accordance with the current state of the art and recognized safety regulations. Nevertheless, hazard may be posed to the life and limb of the individual using the product or to third parties. Risk of damage may be posed to the product or other equipment and property.

Use the AMRF:

solely for its designated use

only when in a safe, perfect condition

Immediately remedy any malfunctions that might impair safety.

Our General Terms and Conditions apply. They are made available to the owner upon concluding purchase of the unit at the latest. Any and all warranty and liability claims for personal injuries and damage to property shall be excluded in the event they are attributable to one or more of the following causes:

Improper use of the AMRF or use deviating from its intended use

improper assembly, installation, commissioning, operation and maintenance of the AMRF

Modifications to the AMRF made by the user or purchaser

improperly performed repair work

Always keep these instructions near the unit.

In addition to the operating instructions, the general and local regulations on accident prevention and environmental protection are to be made available and observed.

Make sure that the safety and hazard symbols and warnings on the unit are always in a legible condition.

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AMRF4 Safety information and instructions

Explanation of Symbols and Warnings, etc.

The following designations and symbols are used in this manual to designate hazards, etc.:

DANGER DANGER denotes situations which can lead to death if safety precautions are not observed.

WARNING WARNING denotes situations which can lead to death if safety precautions are not observed.

CAUTION CAUTION denotes situations which can lead to severe injuries if safety precautions are not observed.

NOTICE NOTICE denotes situations which can lead to property damage if safety precautions are not observed.

Proper/Designated Use

The Automotive MultiRheo Filter AMRF is a stationary filtration unit used for full-flow or bypass filtration of low-viscosity fluids.

Proper or designated use of the product extends to the following:

Maintaining adherence to all the instructions contained herein.

Performing requisite inspection and maintenance work.

Improper use or use deviating from intended use

Improper use may result in hazards.

Example of improper use:

Improper connection of the pressure and return flow hoses and oil leakage pipe.

Noncompliance with the restrictions on use

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AMRF4 Safety information and instructions

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Training and Instruction of Personnel

The AMRF may only be operated by properly trained and instructed personnel.

The areas of responsibility of your staff must be established in a clear-cut manner.

Trainees may only work on the AMRF when supervised by an experienced individual.

Indi

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als

Indi

vidu

als

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ing

Indi

vidu

als

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te

chni

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rain

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en

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erin

g ba

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ound

Ele

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ians

Sup

ervi

sor

with

the

appr

opria

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utho

rity

Activity

Packing / transportation X X X

Commissioning X X X

Operation X X X X

Troubleshooting/ locating the source of malfunction X X X

Troubleshooting, mechanical problem X X

Remedying of electrical faults X X

Maintenance X X X X

Servicing X

Decommissioning / Storage X X X X

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AMRF4 Unpacking AMRF

Dangers by pressure in the hydraulic system

WARNING Hydraulic systems are under pressure

Danger of bodily injury

► The hydraulic system must be depressurized before performing any work on the hydraulic system.

AMRF modification

Do not make any modifications (design modifications, extensions) to the AMRF without the prior consent of the manufacturer.

Immediately replace any unit components which are not in perfect condition.

Use only original spare parts (OEM).

Unpacking AMRF

When receiving and unpacking the unit, check it for damage in transit.

The connectors/ports are closed off so that no contamination can enter the unit while it is in transit.

Dispose of the packaging material as appropriate for your area.

Storing the AMRF

Store the filter in a clean, dry place.

Drain the filter housing completely before putting it into storage.

Check the external corrosion protection (paint coat) for damage, apply a new coat or touch up the existing one as needed.

Wet the cleaned filter interior and all sealing surfaces such as the flange with a suitable corrosion inhibitor, e.g. ANTICORIT 3 by Fuchs-DEA.

Storage temperature: 5 … 30°C

Humidity: up to 50% relative humidity

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AMRF4 Checking the scope of delivery

Checking the scope of delivery

Upon receiving the AMRF check it for any damage in transit. Do not put the AMRF into operation unless it is in perfect condition. Report any damages in transit to the transport company or the responsible agent immediately. Do not put the unit into operation.

The following items are included in the scope of delivery:

Qty. Designation

1 Automotive MultiRheo Filter

1 Installation and Maintenance Instructions (this document)

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AMRF4 Technical Description

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Technical Description

The Automotive MultiRheo Filter AMRF is a stationary filtration unit used for full-flow and bypass filtration of low-viscosity fluids for the separation of particles of 100 … 1 µm (absolute).

The Automotive MultiRheo Filter is part of a filter series for the use of Flexmicron filter elements.

Restrictions pertaining to use

NOTICE

Impermissible operating media

The Automotive MultiRheo Filter will be damaged.

► The unit is only to be used with mineral oils or mineral oil-based raffinates or for cooling lubricants.

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AMRF4 Calculating the pressure differential of the filter housing / filter element

Calculating the pressure differential of the filter housing / filter element

The total pressure of the filters at a specific flow rate is comprised of the housing and the filter element . The pressure loss of the housing can be determined

using the following pressure loss curve. The pressure loss of the filter elements is computed on the basis of the R factors.

p p

Housing : Pressure loss curve, housing p

Dif

fere

nti

al p

ress

ure

(b

ar)

Flow rate (l/min)

The upper housing curve holds for mineral oil with a density of 0.86 kg/dm³ and a kinematics viscosity of 30 mm²/s. The lower housing curve holds for water at 20°C. For turbulent flow, the differential pressure will change proportionally to the density; for laminar flow, it will change proportionally to the density and viscosity. The flow velocity should not exceed 3 m/s at the filter inlet for oil and 4 m/s for water.

Filter element- : pressure loss calculation, filter element p

The following calculation is based on clean filter elements:

1000)(

min)/()/²()(

inchLn

lQsmmVRbarp

R = R Factor

V = viscosity (mm²/s)

Q = flow rate (l/min)

N = Numbers of elements

L = Length of element (inch)

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AMRF4 Calculating the pressure differential of the filter housing / filter element

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R (Resistance) Factors

Filter material

Abbreviation = Designation

PA = Polyamide

PP = Polypropylene

PES = Polyester

GF = Glass fiber

Maximum differential pressure at the filter element

The maximum differential pressure Δpmax and the permitted temperature at the filter element are:

Filter material

Fluid temperature PP PA PES

-10 … 30 °C 4 bar 7 bar 8 bar

-10 … 60 °C 2 bar 5.5 bar 6.5 bar

-10 … 100 °C - 3.5 bar 5 bar

Filter element FlexMicron P (Premium)

Aqueous fluids oils

Filtration rating PES* PES* GF**

1 µm 32.0 10.4 5.4

3 µm 24.0 7.5 -

5 µm 18.0 4.4 4.3

10 µm 17.0 1.8 3.2

20 µm 15.0 1.8 -

30 µm 14.0 0.9 -

40 µm 14.0 0.9 -

* ß > 5,000

** ß > 20,000

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AMRF4 Calculating the pressure differential of the filter housing / filter element

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Filter element FlexMicron S (Standard)

Aqueous fluids

Filtration rating PA PP

1 µm 274 321

3 µm 116 186

5 µm 42 132

10 µm 15 99

20 µm 11 54

30 µm 6 16

40 µm 3.8 12

50 µm 1.9 10

70 µm 1.1 8

90 µm 0.6 6

Filter element FlexMicron E (Economy)

Aqueous fluids

Filtration rating PP

1 µm 37

3 µm 29

5 µm 20

10 µm 11

20 µm 8

30 µm 6.8

40 µm 5.4

50 µm 4.2

70 µm 3.1

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AMRF4 AMRF components

AMRF components

1

4 6 2

3 3

7

8

910

12

5

11

Item Designation

1 Housing

2 Cover

3 Toggle screws

4 O-ring

5 Filter elements

6 Air-vent plug

7 Inlet flange DIN DN80

8 Outlet flange DIN DN80

9 Drain valve, clean side

10 Drain valve, dirt side

11 Clogging indicator

12 Element collet

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AMRF4 Dimensions

Dimensions

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AMRF4 Hydraulic diagram

Hydraulic diagram

Item Designation

1 Air vent

2 Inlet flange (IN)

3 Outlet flange (OUT)

4 Drain valve, clean side

5 Drain valve, dirt side

6 Clogging indicator

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AMRF4 Setting up / fastening AMRF

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Setting up / fastening AMRF

Place the Automotive MultiRheo Filter on a flat horizontal surface that has a sufficient load-carrying capacity and resilience.

Make sure to leave sufficient room, at least 1 m, over the filter housing to change the filter element.

Fasten the filter with suitable floor anchors.

Hydraulic connection of the AMRF

Connect the AMRF hydraulically using a flexible hose connection or pipeline.

Make sure that no vibrations and/or stress from other machinery and equipment are carried over to filter housing. Use expansion joints if necessary.

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AMRF4 Hydraulic connection of the AMRF

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Notes on pipes and hoses

In order to keep the pressure loss as low as possible, use as few threaded connections as possible.

The pressure loss in a hydraulic line depends upon:

Flow rate

Kinematic viscosity

Pipe dimensions

Fluid density

The pressure loss can be estimated for hydraulic oils as follows:

Δp ~ 6.8 * L / d4 * Q * V * D Δp = Pressure differential in [bar]

L = pipe length [m]

d = internal pipe diameter [mm]

Q = Flow rate [l/min]

V = Kinematic viscosity [mm²/s]

D = Density [kg/dm³] Mineral oil-based hydraulic fluid has a density of ~ 0.9 kg/cm³.

This applies to straight pipe runs and hydraulic oils. Additional threaded connections and pipe bends increase the pressure differential.

Keep the height difference between the pump and the oil level in the tank as low as possible.

Hoses must be suitable for suction pressures of at least -0.5 bar.

Constrictions in the connections and lines should be avoided. This could compromise suction output and cause cavitation .

Take note that the nominal size of the connected hoses/piping must be at least as large as the inlet port sizes.

Make sure that no tension or vibrations are carried over to the pump or filter housing when the pipes are connected. Use hoses or expansion joints if necessary.

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AMRF4 Starting up the AMRF

Starting up the AMRF

The Automotive MultiRheo Filter is supplied ex works without any filter elements installed.

Prior to commissioning, insert all filter elements into the filter housing. Proceed as described on page 23 in the chapter "Replacing the filter elements".

Before commissioning, fill and bleed the passive filter housing in each case.

Performing maintenance

WARNING Operating pressure

Danger of bodily injury

► The hydraulic system must be depressurized before performing any work on the hydraulic system.

The AMRF is optionally supplied with an electric differential pressure indicator. This indicates when the filter element change is required.

The MRF can be optionally equipped with an electric back-pressure indicator.

Once the contamination retention capacity of the filter elements has been reached, the clogging indicator responds.

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AMRF4 Replacing the filter elements

Replacing the filter elements

To change the filter elements, proceed as follows:

1. Switch the pump off. 2. Close the shut-off valves to the INLET and

OUTLET.

3. Completely unscrew the air-vent plug (x) in the cover with a size 6 mm Allen wrench.

4. Have a suitable container, approx. 120 liters, handy or guide the draining fluid back to the dirt tank.

Drain the filter housing by opening the drain ball valve of the contaminated side.

Close the drain ball valve once no more fluid escapes.

5. Have a suitable container, approx. 50 liters,

handy or guide the draining fluid back to the dirt tank.

Drain the filter housing by opening the drain ball valve of the clean side.

Close the drain ball valve once no more fluid escapes.

6. Loosen all toggle screws on the cover with a 24 mm box wrench and disengage them.

7. Remove the filter cover and place it on a clean

surface.

Observe the cover's weight of approx. 23 kg.

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AMRF4 Replacing the filter elements

8. Remove the element holding plate in the upwards direction.

9. Remove all filter elements and dispose of them in an environmentally friendly way.

10. Clean the inside of the filter housing of coarse dirt.

11. Prepare the new filter elements by moistening the O-ring on each element with the operating medium.

12. Insert the new elements into the element receptacle by applying pressure while slightly rotating the element.

Do not use excessive force or a hammer, etc.

13. g.

g ring for damage.

Lightly wet the O-ring on the cover with medium.

Clean the sealing surface on the filter housin

Check the housing sealinReplace it if necessary.

14. the filter elements with the element holding plate.Place the element holding plate on and center

15. Clean the sealing surface on the cover. 16. Place the cover centrally on the filter housing it.

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AMRF4 Replacing the filter elements

17. Engage all toggle screws.

18. Tighten the toggle screws with a 24 mm box

wrench crosswise with a maximum of 85 Nm force.

19. Open the locking features to the INLET and OUTLET.

Switch the pump on and fill the filter housing.

20. Unscrew the air bleed screw in the cover.

As soon as oil escapes, screw in the air bleed screw by hand and tighten it firmly.

21. The filter housing is ready for operation.

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AMRF4 Spare parts

Spare parts

Make sure to always indicate the unit designation (see rating plate) and the serial number when ordering spare and wear parts.

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AMRF4 Spare parts

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Item Qty Designation Part no.

101 1 O-ring for tank cover FKM 602369

113 1 Screw plug G ¼“ FKM 617037

124 2 Ball valve for draining G1“ 702406

125 2 Screw plug G1“ FKM 625359

600 1 Clogging indicator *

- 1 "IN" label 3341915

- 1 "OUT" label 3341917

- 2 "DRAIN" label 3207244

- - Filter elements *

* available on request

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AMRF4 Disposing of the AMRF

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Disposing of the AMRF

Please dispose of the packaging material in an environmentally friendly manner.

After dismantling the unit and separating the various materials, dispose of the unit in an environmentally friendly manner.

Customer Service

HYDAC SERVICE GMBH Friedrichsthaler Straße 15a, Werk 13 66540 Neunkirchen-Heinitz

Germany

Telephone: ++49 (0)681 509 883

Telefax: ++49 (0)681 509 324

E-Mail: [email protected]

Technical data

Technical data Number of filter elements 15 pcs.

Material of the housing 1.4301

Volume of housing in l ~ 147 liters

Operating pressure Maximum 10 bar

Material of seals FKM

Housing weight (empty) ~ 165 kg

Permissible operating temperature -10 … 90 °C / 14 … 194 °F

Storage temperature 5 … 30 °C / 41 … 86 °F

Hydraulic port (IN, OUT) DIN2576 DN80 PN10

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AMRF4 Model Code

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Model Code

AMRF 4 E / 15 Q 40 10 F z 0

Filter type AMRF = Automotive Automotive MultiRheo Filter

Filter size 4 = Housing diameter ~ 355 mm

Filter housing material E = Stainless steel

Element quantity 15 = 15 Filter elements

Connection type Q = DIN DN80 PN 10

Element length 30 = 30“

40 = 40“

Pressure range 10 = 10 bar

Material of seals F = FKM

Clogging indicator D32 = Differential pressure gauge

(GW.0/-V-113)

Dz = Piping for retrofitting a differential pressure indicator

z = Without Clogging Indicator See HYDAC brochure for filter clogging indicators (D 7.050...)

Modification ID

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HYDAC FILTER SYSTEMS GMBH Industriegebiet Postfach 1251 66280 Sulzbach/Saar 66273 Sulzbach/Saar Germany Germany Phone: +49 (0) 6897 509 01 Central Fax: +49 (0) 6897 509 846 (Technical Department) Fax: +49 (0) 6897 509 577 (Sales Department) Internet: www.hydac.com E-Mail: [email protected]