HIGH VISCOSITY FILTER SYSTEMS

Transcription

1 HIGH VISCOSITY FILTER SYSTEMS High Viscosity Filter Cart P/N High Viscosity Hand Held P/N Owner's Manual

2 Table of Contents Customer Satisfaction...2 Introduction...3 Typical Applications...3 Operating Instructions Filter Selection and Run Time...5 Filter Cleanliness Levels Viscosity Classification Equivalents...7 Viscosity vs. Temperature Graph...8 System Design Information...9 Troubleshooting...10 Replacement Parts...11 Product Return...12 Contact Trico...12 Customer Satisfaction Trico Corp. is proud of its commitment to quality. All Trico products are guaranteed against defects in workmanship and materials for as long as you own them. Under this guarantee, free repair or replacement will be made to your satisfaction. Normal wear and tear or misuse is not covered under this warranty. For prompt service contact Trico Customer Service at

3 Introduction Thank-you for purchasing this Trico product. In the past choices were very limited when it came to filtering lubricants with viscosities greater than ºF. Now,Trico offers a solution with our filtration systems. The problem with attempting to filter a high viscosity oil with a lower viscosity system is that the pump and filters are not designed to work with higher pressures required to push high viscosity fluids through the system. As a result these low viscosity units operate primarily in bypass mode where little if any of the high-viscosity oil get filtered. That is where Trico s High-Viscosity Gear and Lube Oil Filtration Systems come in. These systems are specifically designed for high-viscosity fluids associated mainly with gear oils and can filter oils up to ºF ( ºC). To ensure that the equipment receives the cleanest oil possible, for increased equipment life, Trico s filtration systems provide twostage filtration. The oil flows through the primary filter first, where coarse particulate is removed. Then the fluid flows through the secondary filter where fine particulate and water are removed. Please read through this manual carefully to learn how to operate and maintain the High Viscosity Filter System correctly. After reading the manual store it in a safe place for future reference. Typical Applications Transferring new fluid from drums or storage tanks to system reservoirs Complementing existing system filtration on a preventative maintenance program. Filtering new fluid before putting into service. For use with fluids such as hydraulic, gear, lube oil, water soluble fluids and coolants. Call factory regarding compatibility. Gear boxes, splash lubrication. 3

4 Operating Instructions 1. Insert the suction wand assembly (hose connected near the pump) or connect to the supply fluid drum/reservoir. Maximum operating temperature is 150ºF. 2. Insert the outlet wand assembly (hose connected after the 2 nd filter) or connect to the transferring drum/reservoir. If filtering oil on existing equipment reservoirs, locate the inlet wand away from the outlet wand to prevent a direct flow path. 3. Verify that the ON/OFF switch is OFF and plug the cord into a 115VAC 18A grounded outlet (3 wire) 4. When using hose clamps, make sure they have a tight fit. 5. Check Filters to make sure they are properly installed. 6. Turn switch to ON position and check outlet wand to verify for oil flow. Allow time for filters to fill with oil on the initial start up. This will vary depending on viscosity. 7. The condition of the filter elements should be monitored by the gauges located on the filter head. When the differential pressure reads 40 psi, turn OFF the filter cart and replace filter elements. Trico filtration systems are equipped with two pressure gauges, to monitor the pressure across the filter. Recommend element replacement is at 40 psi differential. This value should be considered above the clean element pressure. Filter housings have a 42 psi differential bypass. 4

5 Operating Instructions (cont.) 8. Trico filtration systems are equipped with two sample ports. For the most accurate results, do not sample into an open bottle. Use a vacuum bottle sampler, with the plunger removed. 9. The 4gpm filter cart is equipped with a bypass valve and piping. This valve should be kept in the fully closed position when using the filters. Use the bypass for removal of old/used oil only. Filter Selection and Run Time Two commonly asked questions are: How long should I run my filtration system? What size filter should I use? 1. Filter Selection: First you need to determine what cleanliness level is recommended for your oil. Consult your equipment manufacturer when ever possible. A general guideline for gear oil cleanliness is included in the next section. Start with a larger filter and work your way down. A common mistake is over-filtering. The finer the filter, the more frequent the replacement of the elements will be required. Generally speaking, as your oil gets thicker, the filter size should get larger. (See typical cleanliness levels in the next section) 2. Run Time: Kidney loop filtration works best between 6 and 10 turns of your reservoir volume. For simple calculations: Minimum hours of operation = Gallons of oil x 6 = (Divide by 4 for Cart) Maximum hours of operation = Minimum hours x 2 In rare cases, or extremely dirty oil, additional run time may be needed. 5

6 Filter Cleanliness Levels The majority of rotating equipment is manufactured to a class 2 or class 3 fit typical of most industrial operations. Hydraulic components and rotary screw compressors tend to have tighter tolerances in the sliding and rotating elements. Clearances in components are used to establish cleanliness requirements. The best source for cleanliness requirements is from the equipment manufacturer. In general, as the viscosity of the oil increases the cleanliness level decreases. Below is a general guideline for cleanliness levels. ISO Oil Grade Classification Cleanliness Code (R 4 /R 6 /R 14 ) 32 16/14/ /14/ /14/ /15/ /15/ /16/ /16/ /16/ /18/14 6

7 Viscosity Classification Equivalents 7

8 Viscosity vs. Temperature Graph cst 2000 TEMP/VISCOSITY CHART 2000cSt (10,000 SUS) SUS ISO 320 ISO 460 ISO 680 ISO Operable Ranges (50) 20 (68) 30 (86) 40 (104) 50 (122) 60 (140) 70 (158) 80 (176) 90 (194) 100 (212) Temperature in Celcius (F) 8

9 System Design Information Gear Pump Speed Max. Inlet Vacuum Hose 2 ft./sec. Max. Operating Temp.(F) Pump By-Pass Filter By-Pass Maximum Viscosity Seal and Gasket Material 1 GPM Handheld in. of Mercury ft. Long 110 Continuous ~ 150 Limited Use 78 psi 43 psi 1600 cst. / 7500 SUS Viton Gear Pump Speed Max. Inlet Vacuum Hose 2 ft./sec. Max. Operating Temp.(F) Pump By-Pass Filter By-Pass Maximum Viscosity Seal and Gasket Material 4 GPM Cart in. of Mercury ft. Long 110 Continuous ~ 150 Limited Use 105 psi 43 psi 1600 cst. / 7500 SUS Viton 9

10 Troubleshooting PROBLEM CAUSE RECOMMENDATION Pump Noise Cavitation or Aeration ~ Check hose and fittings for suction air leaks. ~ Check inlet for any flow restriction ~ Consider an increase in the suction hose diameter, which will reduce the velocity of the fluid. No Outlet Flow Unit Does Not Start No Power Defective Motor/ Overload Defective Motor ~ Prime the pump. ~ Check the filter as the cause of the restriction to flow. ~ Check for restriction to outlet flow, which should be to atmosphere. ~ Consider an increase in outlet hose diameter, which will reduce the outlet pressure. ~ Turn switch ON, replace if defective. ~ Check power supply ~ Replace motor overload (located in switch housing.) ~ Replace Motor 10

11 Replacement Parts Filter Carts Description Trico Part Number 4gpm Filter Cart Hand Held Mini Description Trico Part Number 1gpm Hand-Held Cart Filters - 6 per case Description Trico Part Number 3 micron Beta micron Beta micron Beta Water 10 micron nominal Hand-Held Filters - 12 per case Description Trico Part Number 3 micron Beta micron Beta Water 10 micron nominal Wands Description Trico Part Number Wand Assembly - Filter Cart Wand Assembly - Hand Held

12 Product Return To return the unit for factory service, a Returned Goods Authorization (RGA) number must be obtained. Obtain a RGA number by calling Trico's Customer Service at Trico may not be able to process a return without a RGA number. When returning a product for factory service: 6 Shipment must be returned prepaid to Trico. It is recommended to ship the package through a carrier that provides proof of delivery; insure the shipment at full product value. 6 Place the RGA number on the outside of the package. 6 Use proper materials for packing the product for shipment. 6 Warranty goods will be repaired or replaced (to the customer's satisfaction) and returned to the customer freight prepaid. 6 For non-warranty repairs, customers will be advised of repair charge prior to repair. Contacting Trico To reach Customer Service call (USA only) or Customer Service is available Monday through Friday from 7:30 am - 5:00 pm, Central time. Customer Service can also be reached by fax, , or write to: Customer Service Trico Corp Hickory Street Pewaukee, WI or custserv@tricocorp.com Trico Corp Hickory Street, Pewaukee, WI /11