MultiRheo Filter MRFD2N - HYDAC Service ... been examined and released by a HYDAC representative....

MultiRheo FilterMRFD2N

Installation and Maintenance Instructions English (translation of original instructions)

Document no.: 3312153b

MRFD2N Imprint

HYDAC FILTER SYSTEMS GMBH en(us) / 32

MoWa MRFD2 3312153b en-us 2012-08-08.doc 2012-08-08

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


© 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.

MRFD2N 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 Danger from pressure in the hydraulic system .....................................................11 MRF modification..................................................................................................11

Transporting the MRFD..........................................................................................12

Storing the MRFD ...................................................................................................13

Checking the scope of delivery.............................................................................14

Technical Description ............................................................................................15

Restrictions pertaining to use ...............................................................................15

Calculating the pressure differential of the filter housing / filter element....................................................................................................................16

Housing : Pressure loss curve, housing..........................................................16 p

Filter element- : pressure loss calculation, filter element .................................16 p

R (Resistance) Factors .........................................................................................17 Filter material ....................................................................................................17 Maximum differential pressure at the filter element ..........................................17 Filter element FlexMicron P (Premium).............................................................17 Filter element FlexMicron S (Standard) ............................................................18 Filter element FlexMicron E (Economy) ............................................................18

MRF components ...................................................................................................19

Dimensions .............................................................................................................21

Hydraulic diagram ..................................................................................................22

Setting up / fastening MRF ....................................................................................23



MRFD2N Content



Hydraulic connection of the MRF .........................................................................23

Notes on pipes and hoses ....................................................................................24

Starting up the MRF ...............................................................................................25

Performing maintenance .......................................................................................25

Changing the Filter Element .................................................................................26 Defining the passive filter housing ....................................................................26

Changing the filter element on the passive filter housing .....................................27

Spare parts..............................................................................................................29

Disposing of the MRF.............................................................................................30

Customer Service...................................................................................................30

Technical data ........................................................................................................30

MRFD2N 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.

Note that the information on the unit's engineering contained in the documentation was that available at the time of publication.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”



MRFD2N Preface



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


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'll find this under www.hydac.com -> Legal information

http://www.hydac.com/

MRFD2N 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.



MRFD2N Safety information and instructions



Safety information and instructions

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

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 product 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, 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 MRF:

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 MRF or use deviating from its designated use

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

modifications to the MRF 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.


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 MultiRheo Filter MRF 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






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.

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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


Danger from 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

MRF modification

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

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

Use only original spare parts (OEM).



MRFD2N Transporting the MRFD

Transporting the MRFD

Transport the MRFD lying flat on a pallet.



MRFD2N Storing the MRFD

Storing the MRFD

Remove all filter elements and completely drain the filter housing. Clean and flush the filter housing

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

Humidity: Up to 80% relative humidity, non-condensing

Air Clean, salt-free air, not near oxidizing substances (rust film).

Storage duration Unlimited

Before the unit is started up again after a storage period of greater than 2 years, all seals must be replaced.

Store the MRFD standing up, or lying flat on a pallet.



MRFD2N Checking the scope of delivery

Checking the scope of delivery

Upon receiving the MRF check it for any damage in transit. Do not put the MRF 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 MultiRheo Filter

1 Installation and Maintenance Instructions (this document)



MRFD2N Technical Description



Technical Description

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

Restrictions pertaining to use

NOTICE

Impermissible operating media

The MultiRheo Filter will be damaged.

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

MRFD2N 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)






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




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

MRFD2N MRF components

MRF components



MRFD2N MRF components



Item Designation

1 Housing

2 Cover

3 Tensioning clamp with safety chain

4 O-ring

6 Air-bleed valve BLEED

7 Inlet flange IN

8 Outlet flange OUT

9 Drain valve, clean side DRAIN

10 Drain valve, dirt side DRAIN

11 Clogging indicator

12 Air-vent plug

13 Change-over valve

14 Filling ball valve

MRFD2N Dimensions

Dimensions



MRFD2N Hydraulic diagram

Hydraulic diagram

Item Designation

6 Air-bleed valve BLEED

7 Inlet flange IN

8 Outlet flange OUT

9 Drain valve, clean side DRAIN

10 Drain valve, dirt side DRAIN

11 Clogging indicator

12 Air-vent plug

13 Change-over valve

14 Filling ball valve



MRFD2N Setting up / fastening MRF



Setting up / fastening MRF

Place the 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 MRF

Connect the MRF 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.

MRFD2N Hydraulic connection of the MRF



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.

MRFD2N Starting up the MRF

Starting up the MRF

The 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 26.

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

Performing maintenance

WARNING Hydraulic systems are under pressure

Danger of bodily injury

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

► Note the tensioning clamp with safety chain of the air bleed screw. Use only the air bleed screw with a safety chain on the tensioning clamp. This has a safety function and ensures that the filter housing is vented before the tensioning clamp is opened.

The MRF is standard equipped with a differential pressure indicator that functions as a clogging indicator.

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



MRFD2N Performing maintenance

Changing the Filter Element

Defining the passive filter housing

Define the passive filter housing before changing the filter elements as follows:

Active Passive Passive Active




Changing the filter element on the passive filter housing

To change the filter elements, proceed as follows:

1. Depressurize the filter housing (1).

Open the air bleed screw (12) in the cover.

2. Open the contaminated side drain (10) and collect the escaping operating fluid with a suitable container.

When operating fluid ceases to come out, close the drain (10).

3. After removing the air bleed screw (10), release the tensioning clamp (3). The safety chain releases the lock of the tensioning clamp so that it can be opened.

4. Remove the cover and place it on a clean surface.

5. Remove all filter elements (5) and dispose of them in an environmentally friendly way.

6. Clean the inside of the filter housing.

7. Moisten the O-ring on the filter element lightly with operating fluid.

8. Insert the new filter elements (5) into the element mount by rotating them slightly while applying pressure to the element.

Do not use excessive force or a hammer, etc.

9. Clean the sealing surface on the housing. Check the O-ring for damage. Replace it if necessary.

Moisten the O-ring (4) with operating fluid and insert it.

10. Clean the sealing surface on the cover (2).

Put the cover on (2).

11. Close the tensioning clamp.

12. Slowly open the filling ball valve (13) in the filling line and ...

13. ... fill the filter housing via the filling line.






If operating fluid escapes from the air bleed screw (12), close the filling ball valve (13) of the filling line.

Screw the air bleed screw in (12) and tighten it securely.

14. The filter housing is ready for operation.

MRFD2N 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.

Item Designation Qty Part no.

3 Tensioning clamp with safety chain and air bleed screw

2 6019642

4 o-ring (cover) 215,49x 3,53-NBR -80Sh

2 617416

11 Clogging indicator 2 *

13 Change-over valve 1 *

*) on request, additional spare parts on request.



MRFD2N Disposing of the MRF



Disposing of the MRF

When decommissioning and/or disposing of the unit, observe all local guidelines and regulations pertaining to occupational safety and environmental protection. This applies in particular to the oil contained in the unit, to components coated in oil and to electronic components.

After disassembling the unit and separating the various materials, reuse them or dispose of them properly in accordance with local regulations.

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


Technical data

Technical data Number of filter elements 2x 7 pcs.

Material of the housing 1.0570, 1.0038

Volume of housing in l 2x ~ 50 liters

Operating pressure maximum 10 bar / 145 psi

Material of seals NBR / FKM

Housing weight (empty) ~ 180 kg

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

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

Hydraulic port (IN, OUT) Depending on version

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]

MultiRheo Filter MRFD2N - HYDAC Service ... been examined and released by a HYDAC representative....

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Transcript of MultiRheo Filter MRFD2N - HYDAC Service ... been examined and released by a HYDAC representative....