BULK OIL FILTRATION UNIT

Transcription

1 Operations Manual for FM41046 Unit # 2193 BULK OIL FILTRATION UNIT Page 1 of 22

2 TABLE OF CONTENTS 1 Introduction 3 2 Calculation of Filtration Time 3 3 Specifications 4 4 System features 5 5 Explanation of Features 7 6 Oil loading process for new elements 8 7 Operation Instructions 9 8 Filter Housings 10 9 Live Oil Sample Point Filter Element Life Element Removal & Refitting Procedure Element Change Procedure System Parts Filter Housing Parts Electrical Schematic Contact Details 22 Page 2 of 22

3 1. INTRODUCTION This mobile filtration system designed to filter the existing oil using the Kidney Loop Filtration process:- Kidney Loop Filtration a filtration process where the oil is pumped from its compartment and directed through the filter element housings and returned to the same compartment of the machine. The oil continues to circulate through this path until cleaned to an acceptable level. 2. CALCULATION OF FILTRATION TIME It is critical to allow adequate filtration time to complete as many cycles of the oil volume as possible. Industry best practice recommends filtering the oil volume by a minimum of seven times to ensure one pass of the oil in the compartment. Filter Technology recommend, where possible, to complete the equivalent of 2 to 3 complete passes, that is 14 to 21 times the volume of the compartment. For example, for a compartment capacity of 800 litres:- 800L x 7 cycles = 5600 litres for one pass L divide by 32L/min flow rate = 175 min. filtration time = 2.9 hours filtration time from one pass = 5.8 hours for 2 complete passes = 8.7 hours for 3 complete passes Page 3 of 22

4 3. SPECIFICATIONS Model Filter Housings Replacement Kit Power Supply Flow Rate Relief Setting Blocked Filter Indication FM off FM Volts 10Amp 15L/min 5 Bar (72.5 PSI) Yes Page 4 of 22

5 4. SYSTEM FEATURES Filter Housings Power Supply Cable Manifold Drain Port Power Supply Plug Live Sample Port Page 5 of 22

6 SYSTEM FEATURES Element Change Light On/Off Isolation Switch Hour Run Metre Emergency-Stop Pressure Gauge Live Sample Port Drip Tray Page 6 of 22

7 5. EXPLANATION OF FEATURES Isolation Switch An Isolation Switch is located to the top left hand corner of the Control Panel. EMERGENCY STOP Button This button is provided for the routine stopping of the system. Hour Run Meter The hour run meter indicates the total hours of operation to date. Element Change Light The Element Change Light will illuminate to indicate that the filter elements require change-out. For further information, see Section 10. Filter Element Life. Pressure Gauge The pressure gauge provides the operator a visual display oil pressure in the filter element housings. Pressure Gauge Page 7 of 22

8 6. Oil Loading Process for New Elements When the FM41046 is first delivered or during a usual service of the filtration unit there is a procedure for the loading of the elements with oil to make the unit operational. If this procedure is not followed the unit will consume an amount of oil that may deplete the volume of the compartment to unsafe levels. Once the filtration unit has been delivered or serviced the process to replenish the new elements is as follows The unit should be placed adjacent to the new oil drum or tote. Attach the unit to a power supply Place the unit into the kidney loop mode (if applicable) Use a suction device to evacuate the oil from the drum or tote Recirculate the oil through the unit back into the drum or tote The unit should be run until pressure of at least 3 bar has been reached this will ensure that the unit has been purged of air and all the elements have been completely encased in oil. Once these conditions have been achieved the suction hose should be removed from the drum or tote and then the unit should be allowed to suck air to pump back as much oil as possible to meet conditions that are usually meet in normal operation. After the unit has pumped as much oil out of its system that is practical it should be stopped isolated and the hoses recoiled back onto the unit ready for general operation. Page 8 of 22

9 7. OPERATION INSTRUCTIONS 1. Place the unit into position near the tank or reservoir that is to be filtered. 2. Attach a suction hose into the nominated take off point. This can be the drain point, and then fit a return hose to the opposite end of the tank or reservoir. This will aid in the cleaning of the compartment. Suction Inlet Point Return Outlet Point 3. Unroll the power lead and plug it into a power source and turn it ON. Plug the power lead into a power source. Page 9 of 22

10 4. The unit is ready to start. Release the Stop Button and Turn the Isolation/Start Switch to the ON position Turn Isolation switch to the ON Position. Release the Emergency Stop button. 5. Allow the unit to run for the time period available. See Section 2. Calculation of Filtration Time for recommended filtration times. 6. When finished, press the red Emergency Stop Button to stop the system. Follow Set-up steps in reverse order to disconnect the system. 8. FILTER HOUSINGS The system is equipped with ten filter housings, each containing four filter elements. See Section 12. Element Change Procedure for details on changing used elements. 9. LIVE OIL SAMPLE POINT One live oil sample point is provided on the pump outlet, before the filters this location provides a representative sample of the oil condition in the compartment. NOTE: As a matter of good practice, when taking any live oil sample, always drain off at least 200ml of oil to flush the sample valve and remove and dead zone oil from behind the sample valve. See Picture below. Page 10 of 22

11 Live Oil Sample point located below the pressure gauge. 10. FILTER ELEMENT LIFE The elements should be changed when:- o The pressure on the gauge rises above 4.5 Bar / 65 PSI with the system at full operating pressure o 500 hours is the recommended maximum element life. Initially, depending on existing oil cleanliness levels, element life may be shorter as residual contamination is removed from each compartment. NOTES 1. The Orange Light on top of the electrical box is to indicate that the elements may require changing. It will activate when the filter inlet pressure exceeds 5 bar The elements must be changed if the Orange Light on top of the electrical box is illuminated. Page 11 of 22

12 11. ELEMENT REMOVAL & REFITTING PROCEDURE 1. Using a clean rag or paper towel, clean away any dirt etc from around the lids of the filter housings. 2. Rotate the housing lid Tee handle anti-clockwise until the thread can be felt to have disengaged in the housing, see Fig Lift the filter assembly only slightly and reposition off-centre so that the centre tube is not engaged in the housing, see Fig. 2. Do not remove element assembly from housing at this stage. 4. Place a drain tray under the drain port, see Fig 4, or connect a waste evacuation hose to the drain port. Allow housings to drain accordingly. 5. Repeat steps 1 to 3 at remaining housings so all can drain ASAP. This will be more effective if the oil is warmer but is worth doing in any case. 6. With a spill container in position, withdraw the used element assemblies from the housings and place them in the spill container to drain further. 7. Change elements on the assembly as per Section 12. Element Change Procedure 8. Insert the clean element assemblies into the housing slowly, being careful not to displace any oil still in the housing causing spillage. 9. Locate the threaded end of the Return tube into the base of the element housing and rotate clockwise to pull the lid into position. Note that there is a lead into the base to make it easier to align and engage the thread, see Fig As the lid engages the housing, take care to ensure the lid seal aligns and enters the housing correctly. 11. Continue to rotate the Tee handle until the lid has pulled up firm on the housing. 12. Rotate the Tee handle 180 to apply final tension to the lid seals. 13. Clean away any spillage. 14. Repeat process on other housings. Page 12 of 22

13 Fig. 1 Element assembly screwed into housing base. Fig. 2 Oil in housing can now drain back to reservoir. Element assembly unscrewed and repositioned off-centre as shown. Fig. 3 Lead into thread Fig. 4 Housing Drain Port Page 13 of 22

14 12. ELEMENT CHANGE PROCEDURE Page 14 of 22

15 Page 15 of 22

16 13. SYSTEM PARTS Item FTA Part Number Technical Description Qty 1 FM3204 Filter Housing No 4 - Industrial 10 2 FM0065 Pressure Gauge ¼ BSP Rear Entry c/w FTA logo 1 3 FMP3010 Live Sample Point 1 4 FMM6012 Live Sample Dust Cover 1 5 FM0348 Relief Manifold 1 6 FM0339 Outlet Manifold 1 7 FM0368 Inlet Manifold 1 8 FME1007 Motor: 240V 0.75kw 1 9 FMP1118 Pump: 15.7cc 1 10 FMP3056 Check Valve 5 Bar x 1" 1 11 FME4005 Pressure Switch High 1 12 FME6292 Emergency Stop Button 1 13 FME6268 Amber Light 240V 1 14 FME5076 Isolation/Start Switch 1 15 FME6251 Hour Run Metre 1 Page 16 of 22

17 SYSTEM PARTS & 4 9 Page 17 of 22

18 SYSTEM PARTS Page 18 of 22

19 SYSTEM PARTS Page 19 of 22

20 14. FILTER HOUSING PARTS Page 20 of 22

21 15. ELECTRICAL SCHEMATIC Page 21 of 22

22 16. CONTACT DETAILS Filter Technology Australia Office: 44 Bonville Ave, Thornton NSW 2322 Postal: PO Box 101, Thornton NSW 2322 Tel: Fax: Toll Free Australia: info@filtertechnology.com.au Page 22 of 22