Risk of damage to the filter from improper filling
If the filter is filled improperly, the filter elements may be damaged.
• Filling the filter against the indicated direction of flow of the filter elements is not permitted.
X Check whether all connections have been made properly.
X Open the shut-off valves in the control line to the differential pressure monitoring system (optional).
X Close the shut-off valve in the by-pass line (if available).
X Completely open the shut-off valve at the filter outlet.
CAUTION!
Risk of damage due to pressure surge in the lubricant circulation Pressure surges in the lubricant circulation can cause damage.
• Only partially open the shut-off valve at the filter inlet before switching on the plant and then open the shut-off valve slowly all the way whilst the plant is running.
X Partially open the shut-off valve at the filter inlet.
X Switch on the plant.
X Slowly open the shut-off valve at the filter inlet all the way.
X Check the pressure downstream of the filter. If it is less than 2 bar, set the operating pressure to the required level by gradually closing the shut-off valve downstream of the filter.
X Check whether the rotary indicator is rotating (= backflushing system in operation) through the inspection glass in the cover.
CAUTION!
Insufficient filtration may cause damage to downstream components If an inadmissible increase in differential pressure occurs during commissioning and whilst the backflushing device is active, a signal is generated by the differential pressure monitoring system and the corresponding message is issued. This can typically be caused by initial contamination in new plants.
Continuing operation can cause damage to downstream components.
• Take the filter out of service and clean all filter elements and if the overflow valves have opened, clean the protective sieve as well.
X The filter is ready for operation.
DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is disposed
36 / 58 Operating instructions 6.48 Betriebsanleitung 6.48 NOTE
When removing the filter and taking it out of service for longer periods, pay attention to the following points:
• Disconnect all connections from the filter.
• The filter must be completely emptied.
• The filter must be thoroughly cleaned.
• If necessary, seal the filter by applying a suitable anti-corrosive.
• The connection flange openings must be sealed with plastic (or similar) dummy plugs.
7.4.1 Disposal DISPOSAL
When the filter or individual components and consumables are finally disposed of, make sure that they are disposed of in an environmentally friendly manner.
8 Maintenance and servicing
8.1 Special safety instructions
DANGER!Risk of accidents from improper maintenance and servicing
Incorrect maintenance and servicing and failure to observe the listed safety instructions can lead to accidents and material damage. Make sure of the following:
• Maintenance and servicing work must only be carried out by qualified specialist staff or persons who have received appropriate instruction.
• When performing any work on the filter, always wear the appropriate safety equipment and clothing.
• Only perform maintenance and servicing work when the filter is cooled, depressurised and empty. Depending on the operating temperature, there may be a risk of burns.
• Ensure the highest levels of cleanliness when opening the filter. No foreign substances, e.g. tools, cleaning cloths, impurities etc., must be allowed to remain in the filter.
• Visually inspect all seals during maintenance and replace them as necessary.
• Clean all sealing surfaces thoroughly before assembly.
• On completion of the maintenance work, re-fit all available safety equipment properly.
• Filling the filter against the indicated direction of flow of the filter elements is not permitted.
• Remove the filter from service if the inspection periods (if indicated) have elapsed.
• Filter elements are sensitive to pressure and impact. Always exercise extreme caution when installing and removing the filter elements. Before installation, check all filter elements/seals and replace any damaged filter elements/seals as necessary.
38 / 58 Operating instructions 6.48 Betriebsanleitung 6.48 CAUTION!
Risk of damage to the filter from incorrect use of cleaning agents
The components of the filter may become damaged if cleaning agents are used incorrectly. The correct cleaning agent is selected in accordance with the type of medium being filtered and the associated contaminations.
• BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning agent. For more detailed information, see the appendix of these operating instructions.
8.3 Special tools
The manufacturer provides the following special tools for the filter:
Tool for removing the filter candles
8.4 Maintenance intervals
Even automatic filters have to undergo regular checks and maintenance.
It is particularly important to note that the filter material on the filter elements may become blocked over time despite permanent backflushing. This depends largely on the quality of medium and the available partial flow cleaning function.
The contamination in the mesh can be removed by cleaning the filter elements by hand using a suitable cleaning agent.
NOTE
BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning agent. For more detailed information, see the appendix of these operating instructions.
An increasing blockage of the filter elements becomes noticeable from an increasing pressure loss in the filter.
In order to make sure the automatic filter continues to operate properly, observe the following points for maintenance:
• Regularly check:
– the differential pressure,
– the leak tightness of the automatic filter, especially all connections and seals and
– the automatic filter for corrosion and other damage, – the flushing oil outlet and the optional nozzle for soiling, – the function of the backflushing device and
– the condition of all screw connections and whether they are firmly tightened.
• The automatic filter must be inspected annually for leaks.
• Replace all seals at least every 2 years and when overhauling.
• Check the condition of the filter elements annually.
If an inadmissibly high level of differential pressure is detected beforehand, all the filter elements must be checked and cleaned as necessary.
If you discover that the protective sieve is heavily contaminated, the automatic filter has been operated for a longer period with contaminated/
faulty filter elements or a faulty backflushing device. The overflow valves have opened from a defined differential pressure level. It is essential that you clean and check the complete filter insert and check that the backflushing device is working.
When regularly checking leak tightness, pay particular attention to the gasket on the inspection glass in the cover which is subjected to dynamic strain.
NOTE
The filter elements are subject to wear from two-way strain. It is therefore recommendable to keep a complete set of filter elements in stock.
NOTE
BOLL & KIRCH Filterbau GmbH recommends you replace all the filter elements at the latest after 4 years.
After carefully inspecting the filter elements they may be usable for a longer period. The user must assume all liability of using filter candles for a longer period.
40 / 58 Operating instructions 6.48 Betriebsanleitung 6.48
8.5 Cleaning/replacing the filter element on the automatic filter
8.5.1 Preparatory work
X Take the plant out of operation or open the shut-off valves of the by-pass line.
X Close the shut-off valves on the connection lines.
DANGER!
Risk of accidents from expelled medium
Hot medium may be expelled when opening the drain hole.
• Proceed with extreme caution.
• Wear the appropriate safety equipment and clothing.
• Collect the expelled medium in a suitable container.
DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is disposed of properly and in an environmentally friendly manner.
X Empty the filter. Carefully open the drain hole.
X Close the drain hole.
X Unfasten the screw connection on the cover.
X Lift the cover off the housing.
8.5.2 Removing the filter insert with filter candles
X Pull the filter insert, including the flushing arms and the cog wheel, out of the housing towards the rotary axis of the flushing arm shaft.
CAUTION!
Damage to the cog wheel
The teeth may become damaged by a build-up of mechanical force.
• Proceed with extreme caution when removing and installing and cleaning the filter insert.
X Allow the filter insert to drip dry in a suitable container.
8.5.3 Cleaning the filter insert with filter candles NOTE
Under normal operating conditions it is not necessary to clean the filter insert manually. The automatic filter cleaning function keeps the pressure loss in the filter constant. if the pressure loss increases above the permitted value, the filter elements need to be cleaned manually. If the overflow valves have opened, the protective sieve must also be cleaned thoroughly.
CAUTION!
Risk of damage to the filter insert from improper cleaning
If the filter insert is cleaned or handled improperly, the filter insert may become damaged. Observe the following safety instructions:
• Proceed with extreme caution when performing all cleaning work.
• The soaking time in the "BOLL CLEAN 2000" cleaning agent must not exceed 24 hours.
• The cleaning temperature, when using "BOLL CLEAN 2000" must not exceed 60 °C.
• When cleaning using a high-pressure cleaner, the pressure must not exceed a maximum of 60 bar. When cleaning using a high-pressure cleaner, keep a sufficient distance (at least 20 cm) from the surface of the filter material to prevent damage.
• Particles of dirt must not be allowed to enter the clean side of the filter element.
• Do not place the filter elements on top of each other as you may otherwise cause damage.
42 / 58 Operating instructions 6.48 Betriebsanleitung 6.48 Cleaning filter elements
Fig. 8-1 Removing the top flushing arm and cover plate
X Unfasten the screws on the top flushing arm and remove the flushing arm from the flushing arm shaft by pulling it upwards.
X Remove the cover plate after unfastening the screws.
X Carefully push or pull all filter elements out of the filter insert using the filter candle removing tool.
NOTE
BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning agent. For more detailed information, see the appendix of these operating instructions.
X Place the filter elements in a container of cleaning agent.
X Remove loose particles which float on the top of the cleaning agent during the soaking stage.
NOTE
BOLL & KIRCH Filterbau GmbH recommend the use of the BOLL & KIRCH cleaning unit with rotating nozzle and flat-jet nozzle for cleaning purposes.
X Clean the individual filter elements over the entire length, from the outside to the inside, using a high-pressure cleaner. When using a rotary nozzle for cleaning, the filter elements can be cleaned from the inside to the outside by inserting the cleaning lance into the filter candle and moving it up and down.
Always hold the filter elements so that the soiling can run off unhindered.
1 Screw 4 Cover plate
2 Top flushing arm 5 Top sieve plate
3 Screw 6 Flushing arm shaft
2 1 3
4
5
6
NOTE
Particles with a borderline grain size which are inside the filter material can be flushed out in both directions of flow.
X Then rinse out the filter elements in fresh cleaning agent.
X Allow the filter elements to dry with one opening pointing downwards or blow the filter elements dry with compressed air.
X Then check all filter elements for damage. Replace any damaged filter elements or seals as necessary.
X Remove any contamination from the other components of the filter element before inserting the filter insert.
X Insert the cleaned filter elements into the filter insert from above with the chamfered end first and push the filter elements all the way into the filter insert. Make sure you do not damage the filter elements as you do so.
X Make sure that the seals are properly in place.
X Re-assembly is performed by repeating the steps for disassembly in reverse order.
Cleaning the protective sieve
X Remove and clean all the filter elements.
X Remove the top sieve plate.
X Remove the protective sieve from the bottom sieve plate.
NOTE
BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning agent. For more detailed information, see the appendix of these operating instructions.
X Place the protective sieve in a container of cleaning agent.
X Remove loose particles which float on the top of the cleaning agent during the soaking stage.
NOTE
BOLL & KIRCH Filterbau GmbH recommend the use of the BOLL & KIRCH cleaning unit with rotating nozzle and flat-jet nozzle for cleaning purposes.
X Clean the protective sieve all over from the inside to the outside, using a high-pressure cleaner.
X Then rinse out the protective sieve in fresh cleaning agent.
X Allow the protective sieve to dry or blow the protective sieve dry with compressed air.
X Then check the protective sieve for damage. Replace the protective sieve if it is damaged.
X Clean all the other components of the candle insert.
X Check the seals for damage. Replace any damaged seals as necessary.
44 / 58 Operating instructions 6.48 Betriebsanleitung 6.48
X Clean any contamination which has collected on the inside of the filter.
X Check all the seals for damage. Replace any damaged seals as necessary.
X Before installation, check that the backflushing device moves freely. The flushing arms must not scrape on the cover plate or the bottom sieve plate.
X Insert the filter insert into the housing with the cog wheel first. As you do so, turn the flushing arms a little as necessary in order to engage the pair of cog wheels.
8.5.5 Concluding work
X Check the seals for damage. Replace any damaged seals as necessary.
X Fit the cover. Make sure that the seal is properly in place. Tighten the screw connection evenly, gradually tightening opposite screws step-by-step.
X Put the filter back into operation. See the section "Commissioning".
8.6 Remedying faults
NOTEIn case of any faults or repairs which are not listed here, contact the BOLL &
KIRCH customer services department.
46 / 58 Operating instructions 6.48
Viscosity too high Wait for normal operating conditions.
High level of dirt Check that the partial flow preparation is fully
- Operating pressure < 2 bar
Increase the operating pressure by slowly closing the shut-off valve downstream of the filter. If necessary, increase the operating pressure to 5 - 6 bar for a longer period in order to accelerate the process of cleaning the filter elements.
- Flushing oil outlet or nozzle (optional)
- Turbine is stuck Remove the foreign bodies from between the turbine and housing wall.
- Worm gear pair defective
Check that the gear unit moves freely and replace the gear unit as
necessary.
- The flushing arms are stuck
- Flow rate too low Increase the flow rate of medium through the filter.
9 Appendix
9.1 Filter
9.1.1 Technical data
Filter
Filter type 6.48
Nominal connection diameter DN 200
Housing size 150
Flow rate 331.00 m³/h
Fine filter units 30 µm
Mesh number 350/350
Permitted operating pressure 10.00 bar permitted max. operating temperature 80.00 °C
Backflushing medium Internal medium
sound emission (DIN 45 635) < 70 dB(A)
Filter element
Element type of filter Mesh candle
Number of filter elements 60
48 / 58 Operating instructions 6.48 Betriebsanleitung 6.48
9.1.3 Spare parts
9.1.3.1 Spare parts drawing
50 / 58 Operating instructions 6.48
Item ID no. Description Qty Unit
00001 6530087 Housing 1 pcs.
00007 1340028 Filter Element according to orde 60 pcs.
00008 5700122 safety sieve 1 pcs.
00047 5151868 wheel hub tip 1 pcs.
Item ID no. Description Qty Unit
52 / 58 Operating instructions 6.48 Betriebsanleitung 6.48
00112 3040040 Gasket 2 pcs.
00120 2000132 hexagon socket head cap screw 4 pcs.
00123 2000156 hexagon socket head cap screw 2 pcs.
00130 2700019 Deep Groove Ball Bearing 2 pcs.
00150 2000134 hexagon socket head cap screw 4 pcs.
00192 5000296 streaming guide 1 pcs.
00193 2000531 stud bolt 1 pcs.
00194 5000332 guide ring 1 pcs.
00195 9100008 candles tool kit for backflushin 1 pcs.
9.2 Differential pressure indicator
9.2.1 Technical data sheet54 / 58 Operating instructions 6.48 Betriebsanleitung 6.48
9.3 Supplier's documentation
NOTEDocumentation for any components or assembly groups purchased externally by BOLL & KIRCH Filterbau GmbH is enclosed with these operating instructions.
Adhere to the information contained, in particular information on the subject of safety.
9.4 Cleaning devices
For particularly good cleaning results, BOLL & KIRCH Filterbau GmbH recommends the filter element cleaning unit type 5.04 with rotating nozzle and flat jet nozzle or optionally, the type 5.05 ultrasonic cleaning unit.
56 / 58 Operating instructions 6.48 Betriebsanleitung 6.48
9.5 BOLL CLEAN 2000 cleaning agent product information
Product description:BOLL CLEAN 2000 is a liquid cleaning and degreasing agent with a broad range of applications. It can be used practically for all cleaning and degreasing needs.
BOLL CLEAN 2000 cleans quickly and thoroughly and is extremely economical.
The use of BOLL CLEAN 2000 renders all safety precautions unnecessary.
BOLL CLEAN 2000 has all these excellent characteristics without the disadvantages of solvent-based cleaners.
BOLL CLEAN 2000 is:
• not inflammable
• not subject to compulsory identification markings
• not strong smelling
• not corrosive
• physiologically harmless
• biodegradable
• Umweltbundesamt (Federal German Ministry of Environment) reg. no.
04860019
BOLL CLEAN 2000 can be overcooled or overheated during storage but is then fully useable when at normal temperature again.
Sieve mesh contaminated with heavy oil:
Sieve meshes which are contaminated with heavy oil must be soaked in normal, commercially available solvent. After soaking, the sieves are cleaned in the BOLL & KIRCH cleaning device type 5.04 with BOLL CLEAN 2000 and high-pressure pump.
Instructions for use:
BOLL CLEAN 2000 is not processed for any specific cleaning method. BOLL CLEAN 2000 can be used in a soaking bath, in a spray unit, in a steam jet cleaner or be applied by hand, using a cloth, brush or sponge, depending on the operational conditions.
It can be used cold or warm.
BOLL CLEAN 2000 can be mixed with water - even with sea water.
• Concentration for mesh cleaning: 1 : 2,5
• Maximum temperature up to 60 °C
The concentration depends on the type and extent of the collected dirt particles which have to be removed. When using a concentration of 1 : 30 and above, rinsing is usually not necessary. No visible film is left on the surface.
9.6 Worldwide sales and service network, subsidiaries and representatives
If you require service or spare parts, please contact the main site or our subsidiaries, representatives or service points.
Deutschland Croatia Poland
1 2 3BOLL & KIRCH Filterbau GmbH 1 Marine Trade d.o.o. 1 TRIMOR sp. z o. o.
Postfach 1420, D-50143 Kerpen Vladimira Nazora 6 ul. Andersa 17
Siemensstr. 10-14, D-50170 Kerpen HR - 47000 Karlovac PL-81-831 Sopot
Tel.: +49/(0)2273/562-0 Tel.: +385/(0)47/ 61 19 07 Tel.: +48/(0)58 551 66 40
Fax: +49/(0)2273/562-223 Fax: +385/(0)47/ 43 12 61 Fax: +48/(0)58 555 19 29
E-Mail: [email protected] E-Mail: [email protected] E-Mail: [email protected]
www.bollfilter.de www.trimor.com.pl
Cyprus
1 3BOLL & KIRCH Filterbau GmbH 1 M.I.E. Services Ltd. Russia / Ukraine / Belarus
Geschäftsstelle Nord The Hawk Building 1 2 3000 BOLLFILTER Russland
An der Strusbek 34 124 Gladstonos Street Datschnyi prospekt, 2
D - 22926 Ahrensburg CY - 3032 Limassol Geb. 1, Lit. A, Raum 23N
Tel.: +49/(0)4102/4740-0 Tel.: +357/(0)25 889 999 RUS - 198207 St. Petersburg
Fax: +49/(0)4102/4740-22 Fax: +357/(0)25 763 902 Tel.: + 7/(0)812-364-61-80
E-Mail: [email protected] E-Mail: [email protected] Fax: + 7/(0)812-364-61-80
www.bollfilter.de E-Mail: [email protected]
1 IVG Pumpen- und Filtrationstechnik Gera Denmark / Sweden / Norway / 1 2 3Switzerland / Liechtenstein
Prehlis 13 A Iceland / Finland / Lithuania / EIG CRUSTAG
D - 07552 Gera Latvia / Estonia 120 Route de Frontenex
Tel.:+49/(0)365/42 00 07 4 1 2 3BOLLFILTER Nordic ApS CH - 1208 Genève
Fax: +49/(0)365/42 00 07 5 Hammerbakken 21 Tel.: +41/(0)22/73 59 50 0
E-Mail: [email protected] DK - 3460 Birkerød Fax: +41/(0)22/78 66 17 1
www.ivg-neubert.de Tel.: +45/(0)45/42 12 00 E-Mail: [email protected]
Fax: +45/(0)45/42 12 99 www.eig-crustag.ch
1 BOLL & KIRCH Filterbau GmbH E-Mail: [email protected]
Geschäftsstelle Süd www.bollfilter.dk 1 2 3Spain / Portugal / Argentina /
Rangaustraße 7a Chile / Peru / Uruguay
D - 91639 Wolframs-Eschenbach BOLLFILTER España S.L.
Tel.: +49/(0)9875/884 (Herr Henkelmann) Greece / Bulgaria Zona Cami Ral
Tel.: +49/(0)9875/971 865 (Herr Pirkl) 1 2 3FILTERKON Paseo del Ferrocarril, 339 3ª – 2a
Fax: +49/(0)9875/885 8, Mitsaion Str. E - 08860 Castelldefels
E-Mail: [email protected] GR - 117 42 Athen Tel.: +34/(0)93/634 26 80
www.bollfilter.de Tel.: +30/(0)210/92 17 671 Fax: +34/(0)93/665 22 79
Fax: +30/(0)210/92 42 242 E-Mail: [email protected] E-Mail: [email protected] www.bollfilter.com
Austria / www.filterkon.com
Czech Republic / 1 2 3The Netherlands
Slovakia / Slovenia Great Britain and Ireland Lubrafil B.V.
Slovakia / Slovenia Great Britain and Ireland Lubrafil B.V.