MRF 2 NU - Start: HYDAC · PDF fileMRF 2 NU MultiRheo Filter Preface We have compiled this...

MRF 2 NU MultiRheo Filter

Operating and Maintenance Instructions English

Doc.: 3341025


Trademarks The trademarks used herein of other companies exclusively designate the products of these companies.

Copyright © 2007 by HYDAC Filtertechnik GmbH All rights reserved No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose, without the express written consent of HYDAC Filtertechnik. Any violation hereof will be prosecuted to the maximum extent possible under the law.

Exclusion of Liability Every effort has been taken to ensure that the information provided herein is correct, however errors cannot be precluded. The information contained herein does not represent a commitment on the part of the authors. Consequently, no liability is assumed for any errors or omissions inherent in this document, including consequential damage or loss. The information provided herein is checked on a regular basis, with corrections being entered in subsequent editions. Any remarks or suggestions for improvement you might have would be appreciated.

All technical details are subject to change without notice.

The content of this manual is subject to change without notice.

HYDAC FILTERTECHNIK GmbH

Industriegebiet

D-66280 Sulzbach / Saar

Germany

Phone: ++49 (0) 6897 / 509 – 01

Fax: ++49 (0) 6897 / 509 – 846

HYDAC Filtertechnik GmbH en

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Contents

Contents..................................................................................................................................3 Preface ....................................................................................................................................4

Customer Service .................................................................................................................5 Modifications to the Product .................................................................................................5 Warranty ...............................................................................................................................5

1 General Safety Guidelines..............................................................................................7 1.1 Obligations and Liability.................................................................................................7 1.2 Explanation of Symbols and Warnings, etc. ..................................................................7

1.2.1 Basic Symbols........................................................................................................8 1.3 Proper/Designated Use .................................................................................................8 1.4 Improper Use.................................................................................................................8 1.5 Safety Devices and Equipment .....................................................................................8 1.6 Informal Safety Precautions ..........................................................................................9 1.7 Training and Instruction of Personnel............................................................................9 1.8 Safety Measures to Be Followed during Normal Operation ........................................10 1.9 Hazards Posed by Stored Residual Energy ................................................................10 1.10 Modifications to the MRF.............................................................................................10

2 Included with the Filter As Supplied ...........................................................................11 3 Installation .....................................................................................................................11

3.1 Hydraulic Hook-up .......................................................................................................11 3.1.1 Remarks Pertaining to Piping / Tubing.................................................................12

4 Commissioning .............................................................................................................13 5 Maintenance and Servicing..........................................................................................14

5.1 General........................................................................................................................14 5.2 Maintenance Measures ...............................................................................................14 5.3 Frequency of Changing the Filter Elements ................................................................14

6 Changing Filter Elements.............................................................................................15 6.1 Removing the Filter Elements .....................................................................................15 6.2 Installing a New Filter Element ....................................................................................16

7 Replacement Parts / Dimensions ................................................................................17 7.1 Spare Parts List ...........................................................................................................18

8 Technical Specification ................................................................................................18


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Preface We have compiled this manual for you, the user of our product. It contains the most important information relating to operation and maintenance.

It is intended to help you become acquainted with the proper/designated use 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 the documentation cannot always keep pace 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.

In these cases we go to every effort to keep your documentation current by sending you updates.

But we need your help. Please make sure that you incorporate the updates in your documentation and that non-current sections are removed.

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

HYDAC Filtertechnik GmbH Abteilung SVFM, Technische Dokumentation Postfach 12 51 D-66273 Sulzbach/Saar, Germany

Fax: ++49 (0) 6897 509 846 E-mail: [email protected]

We look forward to receiving your input.

Our motto: “Putting experience into practice”


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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 Filtertechnik GmbH.

They are available at: www.hydac.com Legal information.


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http://www.hydac.com/


... And now for a few tips on using this documentation.

The following example shows you how you can access the information you are looking for quick and easy.

WHAT do you want to know?

WHERE can you find the information you're looking for?

The documentation is subdivided into chapters and sections.

Look for the table of contents.

Skim the boldfaced section headings.

HOW can you find the section and page you're looking for?

Page through the operating instructions, keeping your eyes focused on the lower right corner.

As soon as you see the page number you are looking for, stop paging.

The chapter/section heading is featured in the upper right corner of each page.

n

The documentation number/edition and index arepage and on the cover sheet of the manual. This information features the following format:

B

The documentation no. is a stock no. which is useThe index is incremented every time the manual i

Please note that the method describeddoes not release you from your responmanual prior to starting the unit up for manual at regular intervals later on.

HYDAC Filtertechnik GmbH en BeWa MRF2NU 3341025 en.doc

Product designatio
Page no. Edition date of chapter/section
featured in the lower left corner of each

n
Documentation no.
d to order the mans revised or chang

above of locatingsibility for carefullythe first time and c

Index

eWa Product 12345678a e

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specific information reading the entire arefully rereading the

2007-09-24


1 General Safety Guidelines These operating instructions contain the key instructions for properly and safely operating the MRF.

1.1 Obligations and Liability • The basic prerequisite for the safe and proper handling and operation of the MRF is

knowledge of the safety instructions and warnings.

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

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

• The safety precautions listed herein are limited solely to using the MRF.

The MRF has been designed and constructed in accordance with the current state of the art and recognized safety regulations. Nevertheless, hazards may be posed to the life and limb of the individual using the unit or to third parties. Risk of damage may be posed to the unit or other equipment and property. The MRF is to be used as follows:

• solely for its designated use

• only when in a safe, perfect condition

• Any faults or malfunctions which might impair safety are to be properly repaired or remedied immediately.

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 MRF or use deviating from its designated use

• improper assembly, installation, commissioning, operation and maintenance of the MRF

• operating the MRF when the system equipment or systems are defective

• modifications to the MRF made by the user or purchaser

• improper monitoring of unit components subject to wear and tear

• improperly performed repair work

1.2 Explanation of Symbols and Warnings, etc. The following designations and symbols are used in this manual to designate hazards, etc.:


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1.2.1 Basic Symbols

This symbol designates safety instructions whose non-observance may pose a hazard to individuals.

This symbol designates safety instructions whose non-observance may result in the injury of individuals by electric shock.

This symbol designates safety instructions whose non-observance may pose a hazard to individuals working on the pressurized system or its components.

This symbol provides important instructions and tips for the proper handling and operation of the MRF. Non-adherence to these instructions may result in damage to the MRF or in damage to its immediate surroundings.

This symbol designates tips for usage and other particularly useful information.

This information helps you to optimally utilize all the features offered by your MRF.

1.3 Proper/Designated Use The MultiRheoFilter (MRF) is a stationary filtration unit used for the full-flow and bypass filtration of low-viscosity fluids.

Any use deviating from what is specified herein shall constitute improper use.

The manufacturer will assume no liability for any loss or damage as the result thereof.

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

• Maintaining adherence to all the instructions contained herein.

• Performing requisite inspection and maintenance work.

1.4 Improper Use Any use deviating from the proper/designated use described above is prohibited.

Improper use may result in hazard to life and limb.

1.5 Safety Devices and Equipment Prior to starting up the filter unit each time, make sure that all the protective safety devices are properly installed and are in proper working order.


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1.6 Informal Safety Precautions Make sure to always keep the operating instructions in the vicinity of the unit.

Apart from the operating instructions, any and all general and local regulations pertaining to accident prevention and environmental protection are to be made available and observance to be maintained to them.

Make sure to keep the safety and hazard symbols and warnings on the unit in a legible condition.

Check the unit daily for leaking (perform a visual check). Replace any loose connections or fittings immediately.

1.7 Training and Instruction of Personnel The MRF 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.

Staff undergoing training may not use the MRF unless supervised by an experienced staff member.

Individuals

Activity

Individuals undergoing

training

Individuals with technical

training/engineering background

Qualified electrician

Supervisor with the appropriate

authority

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

Troubleshooting, electrical problem X X

Maintenance and servicing X X X X

Repair work X

Decommissioning/ putting into storage X X X X


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1.8 Safety Measures to Be Followed during Normal Operation The unit is to be checked once a day for external damage and the proper functioning of the safety devices.

1.9 Hazards Posed by Stored Residual Energy Note that the unit may pose a hazard as the result of residual stored mechanical and electrical energy. Take the proper precautions when instructing personnel on the use of the unit. Detailed information is provided in the respective sections of this manual.

1.10 Modifications to the MRF Do not make any modifications (design modifications, extensions) to the MRF without the approval of the manufacturer.

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

Only use original replacement parts. When using non-OEM components it cannot be ensured that they have been designed and manufactured so as to comply with loading and safety requirements.


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2 Included with the Filter As Supplied Upon receiving the MRF check it for any damage in transit. The MRF may not be set up and installed unless it is in perfect order. Any damage in transit is to be reported to the forwarding agent or the HYDAC department in charge immediately; the unit may not be commissioned until this damage is properly remedied.

The MRF comes with the following:

Item Qty Designation

1 1 MultiRheo Filter MRF 2 NU

- 1 Operating and Maintenance Instructions (this document)

3 Installation Before integrating the filter in the system make sure that the rated maximum operating system pressure does not exceed that of the MRF (see rating plate).

The filter unit has to be set up in a horizontal position on a level surface. The filter unit needs to be secured to the floor using floor anchors.

Make sure that there is sufficient space above the filter housing as this is needed for removing the filter elements.

3.1 Hydraulic Hook-up Connection to the hydraulic system is to be done using flexible tubing or piping. Make sure that no vibrations or stress/loading from other machinery and equipment are carried over to the filter housing. If necessary, use expansion joints.


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3.1.1 Remarks Pertaining to Piping / Tubing The number of screwed fittings used is to be kept to a minimum so as to minimize pressure loss.

The pressure loss in a hydraulic line is dependent on the following factors:

• Flow rate • Kinematic viscosity • Line dimensions • Density of medium It can be approximated for hydraulic oils as follows:

ρυ ××××≈∆ QdLbarp 48.6][

L = line length [m]

d = inside line diameter [mm]

Q = volumetric flow rate [l/min]

ϑ = kinematic viscosity [mm²/s]

ρ = density [kg/dm³] of mineral oil

≈ 0.9 kg/dm³ This applies to level piping and the use of hydraulic oil grades. Additional screwed fittings and pipe bends result in an increase in the pressure differential.

The difference in the elevation of the filter unit in relation to the oil level should be kept as small as possible. The hoses have to be suitable for a minimum pressure of -0.5 bar and the maximum operating pressure of the filter housing.

Bottlenecks or narrow places in the connecting lines are to be avoided as the flow rate is reduced and a cavitation hazard is posed.

The nominal width of the connecting line must correspond at minimum to the cross-sections of the connector threads or the connector flange.


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4 Commissioning Prior to commissioning, check to see that the filter elements have been installed in the housing. For more information, see the section on Changing the Filter Elements.

Checking the filter elements: 1. Carefully undo the safety screws (1) (with chain) on the cover plate.

2. Open the quick-action fasteners and lift up the cover plates.

3. Make sure that the filter elements have been correctly inserted.

4. Lightly oil or grease the flanges.

5. Place the housing cover on the flanges of the tank.

6. Apply the quick-action fasteners (6), align them and close them. (tightening torque = 27 Nm)

7. Screw the safety screws (1) back in.

Filling and air-bleeding: 1. The "dirt side" oil drain plug (2) and the "clean side" oil drain screw plug (3) have to be

closed tight.

2. Open the air-bleed valve (4) on the cover plate.

3. Fill the filter slowly via the system.

4. After the air in the filter has escaped completely, close the air-bleed valve (4) on the cover plate.

5. Check the filter unit for leakage.

6

1

1

2

7

INOUT

48


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5 Maintenance and Servicing

5.1 General Below follows a description of the maintenance and servicing to be performed at regular intervals. The filter’s serviceability, operational reliability and service life substantially depend on performing maintenance and servicing work regularly and carefully.

5.2 Maintenance Measures • The replacement parts have to satisfy the manufacturer’s technical specifications. This is

ensured when HYDAC original parts are used.

• Tools, working area and equipment are to be kept clean.

• After taking the filter apart, clean all components, checking them for damage or wear. If necessary, replace them.

• When replacing a filter element, extreme care is to be taken that no dirt or other foreign matter is introduced.

5.3 Frequency of Changing the Filter Elements The filter is equipped with a clogging indicator for monitoring the filter elements.

When the clogging indicator is triggered this shows that the filter element has to be replaced immediately.

When no clogging indicator has been fitted, we recommend that elements be changed in specific intervals, however at least once a year. (The frequency of changing the filter elements depends on the filter design and the conditions under which the filter is operated.)

When filter elements are subjected to high dynamic loading it may prove necessary to change them more frequently. The same applies to commissioning, repair work or hydraulic fluid oil changes.

Standard clogging indicators are not triggered unless there is a flow through the filter. As to electrical clogging indicators, the output signal can also be processed and indicated on the control panel continuously until acknowledging the fault by eliminating it (i.e. changing the filter element(s) and cold-starting the system).

If the clogging indicator is only triggered upon cold-starting, this may indicate that the filter element(s) may not yet require changing.


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6 Changing Filter Elements

6.1 Removing the Filter Elements

6

1

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2

7

INOUT

48

1. Open the air-bleed valve (4) on the cover plate to relieve the pressure. Open the "dirt side" drain plug (2) and drain off the dirty fluid into a suitable receptacle. (This fluid may not be reintroduced into the system unless it has been filtered and cleaned.)

2. Open the safety screw (1) (with chain) on the cover plate, then loosen the quick-action fastener (6), and lift up the housing cover.

3. Pull out the filter elements (examine the surface of the filter elements for residual dirt and large size particles. This is often an indication of possible component damage.)

4. Remove the filter elements.

5. Clean the housing and cover plate, if necessary.

6. Examine the filter for mechanical damage, taking a good look at the sealing surfaces in particular.

7. Check the O-rings (8) and replace them, if necessary.


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6.2 Installing a New Filter Element

6

1

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2

7

INOUT

48

To install a new filter element, proceed as follows:

1. Moisten the sealing surfaces on the filter housing and the cover plate, including the O-ring (8), if necessary, with clean operating fluid.

2. When installing a new filter element, check to see whether the designation on the new element corresponds to the designation on the old one.

3. Wet the O-ring of the new element with hydraulic fluid.

4. Carefully place the filter element onto the element location spigot in the housing (note the position of the handle on the element).

5. Place the housing cover on the flange of the tank. Apply the quick-action fastener (6), align it and close it (tightening torque of screw = 27 Nm).

6. Screw in the safety screw (1) (with chain).

7. Close the "dirt side" drain plug (2).

8. Fill the filter side until oil exits at the air-bleed valve (4).

9. Close the air-bleed valve (4) in that line.

10. Check the filter for leaking.

Filter elements which cannot be cleaned are to be disposed of in an environmentally safe and sound manner.


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7 Replacement Parts / Dimensions


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7.1 Spare Parts List

Item Designation Qty Stock no.

- Filter element, 120 µm N40DR120-PP1F 7 3199894

6 Quick-action fastener 1 6019642

2 Drain screw plug VSTI G 3/4-ED-St /NBR 1 607167

3 Drain screw plug VSTI G 1/2-ED-St /NBR 1 607166

4 Air-bleed valve 1 702164

8 O-ring (cover plate) 215,49x 3,53-NBR -80Sh 2 617416

9 Clogging indicator VL 2 GW.0 /-V-113 2 1285170 For other spare parts, please inquire with us.

8 Technical Specification

MRF2/xx Quantity of filter elements, Nx0xRxxx-Pxx 7

Permissible pressure at element p∆ See element data sheet

Material of housing C-steel

Volume of housing in l 38

Operating pressure in bar, max. 10

Material of seals/gaskets NBR

Weight, housing, in kg ca. 180

Fluid temperature in °C -10 – +100

Ambient temperature in °C 10 – 40

Hydraulic port (IN, OUT) SAE 2" (DIN DN 50)


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HYDAC Filtertechnik GmbH Bereich Servicetechnik / Service Technology Division Industriegebiet Postfach 1251 66280 Sulzbach/Saar 66273 Sulzbach/Saar Germany Germany Phone: +49 (0) 6897 509 01 Fax: +49 (0) 6897 509 846 (Technical Department) Fax: +49 (0) 6897 509 577 (Sales Department) Internet: www.hydac.com E-mail: [email protected]

MRF 2 NU - Start: HYDAC · PDF fileMRF 2 NU MultiRheo Filter Preface We have compiled this...

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