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AMRF4
Automotive MultiRheo Filter 10 bar
Installation and Maintenance InstructionsEnglish (translation of original instructions)
Document No.: 3728735
AMRF4 Imprint
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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
E-Mail: [email protected]
© 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.
AMRF4 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 Dangers by pressure in the hydraulic system.......................................................11 AMRF modification ...............................................................................................11
Unpacking AMRF....................................................................................................11
Storing the AMRF ...................................................................................................11
Checking the scope of delivery.............................................................................12
Technical Description ............................................................................................13
Restrictions pertaining to use ...............................................................................13
Calculating the pressure differential of the filter housing / filter element....................................................................................................................14
Housing : Pressure loss curve, housing..........................................................14 p
Filter element- : pressure loss calculation, filter element .................................14 p
R (Resistance) Factors .........................................................................................15 Filter material ....................................................................................................15 Maximum differential pressure at the filter element ..........................................15 Filter element FlexMicron P (Premium).............................................................15 Filter element FlexMicron S (Standard) ............................................................16 Filter element FlexMicron E (Economy) ............................................................16
AMRF components.................................................................................................17
Dimensions .............................................................................................................18
Hydraulic diagram ..................................................................................................19
Setting up / fastening AMRF..................................................................................20
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AMRF4 Content
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Hydraulic connection of the AMRF.......................................................................20
Notes on pipes and hoses ....................................................................................21
Starting up the AMRF.............................................................................................22
Performing maintenance .......................................................................................22
Replacing the filter elements ................................................................................23
Spare parts..............................................................................................................26
Disposing of the AMRF..........................................................................................28
Customer Service...................................................................................................28
Technical data ........................................................................................................28
Model Code .............................................................................................................29
AMRF4 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.
Sometimes the information contained in this documentation cannot always keep up 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.
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”
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AMRF4 Preface
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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 Filter Systems GmbH.
You will find these under www.hydac.com -> General terms and conditions.
AMRF4 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.
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AMRF4 Safety information and instructions
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Safety information and instructions
These installation and maintenance instructions contain the key instructions for properly and safely operating the AMRF.
Obligations and liability
The basic prerequisite for the safe and proper handling and operation of the AMRF is knowledge of the safety precautions and regulations.
These operating instructions in general, and the safety precautions in particular, are to be adhered by all those who work with the AMRF.
Adherence is to be maintained to pertinent accident prevention regulations applicable at the site where the product is used.
The safety guidelines listed here are restricted to use of the AMRF.
The AMRF 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 AMRF:
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 AMRF or use deviating from its intended use
improper assembly, installation, commissioning, operation and maintenance of the AMRF
Modifications to the AMRF 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.
AMRF4 Safety information and instructions
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 Automotive MultiRheo Filter AMRF 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
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AMRF4 Safety information and instructions
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Training and Instruction of Personnel
The AMRF 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.
Trainees may only work on the AMRF when supervised by an experienced individual.
Indi
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als
Indi
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als
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ing
Indi
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als
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Ele
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Sup
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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
AMRF4 Unpacking AMRF
Dangers by 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.
AMRF modification
Do not make any modifications (design modifications, extensions) to the AMRF without the prior consent of the manufacturer.
Immediately replace any unit components which are not in perfect condition.
Use only original spare parts (OEM).
Unpacking AMRF
When receiving and unpacking the unit, check it for damage in transit.
The connectors/ports are closed off so that no contamination can enter the unit while it is in transit.
Dispose of the packaging material as appropriate for your area.
Storing the AMRF
Store the filter in a clean, dry place.
Drain the filter housing completely before putting it into storage.
Check the external corrosion protection (paint coat) for damage, apply a new coat or touch up the existing one as needed.
Wet the cleaned filter interior and all sealing surfaces such as the flange with a suitable corrosion inhibitor, e.g. ANTICORIT 3 by Fuchs-DEA.
Storage temperature: 5 … 30°C
Humidity: up to 50% relative humidity
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AMRF4 Checking the scope of delivery
Checking the scope of delivery
Upon receiving the AMRF check it for any damage in transit. Do not put the AMRF 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 Automotive MultiRheo Filter
1 Installation and Maintenance Instructions (this document)
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AMRF4 Technical Description
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Technical Description
The Automotive MultiRheo Filter AMRF 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 Automotive MultiRheo Filter is part of a filter series for the use of Flexmicron filter elements.
Restrictions pertaining to use
NOTICE
Impermissible operating media
The Automotive MultiRheo Filter will be damaged.
► The unit is only to be used with mineral oils or mineral oil-based raffinates or for cooling lubricants.
AMRF4 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)
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AMRF4 Calculating the pressure differential of the filter housing / filter element
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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
AMRF4 Calculating the pressure differential of the filter housing / filter element
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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
AMRF4 AMRF components
AMRF components
1
4 6 2
3 3
7
8
910
12
5
11
Item Designation
1 Housing
2 Cover
3 Toggle screws
4 O-ring
5 Filter elements
6 Air-vent plug
7 Inlet flange DIN DN80
8 Outlet flange DIN DN80
9 Drain valve, clean side
10 Drain valve, dirt side
11 Clogging indicator
12 Element collet
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AMRF4 Dimensions
Dimensions
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AMRF4 Hydraulic diagram
Hydraulic diagram
Item Designation
1 Air vent
2 Inlet flange (IN)
3 Outlet flange (OUT)
4 Drain valve, clean side
5 Drain valve, dirt side
6 Clogging indicator
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AMRF4 Setting up / fastening AMRF
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Setting up / fastening AMRF
Place the Automotive 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 AMRF
Connect the AMRF 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.
AMRF4 Hydraulic connection of the AMRF
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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.
AMRF4 Starting up the AMRF
Starting up the AMRF
The Automotive 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 23 in the chapter "Replacing the filter elements".
Before commissioning, fill and bleed the passive filter housing in each case.
Performing maintenance
WARNING Operating pressure
Danger of bodily injury
► The hydraulic system must be depressurized before performing any work on the hydraulic system.
The AMRF is optionally supplied with an electric differential pressure indicator. This indicates when the filter element change is required.
The MRF can be optionally equipped with an electric back-pressure indicator.
Once the contamination retention capacity of the filter elements has been reached, the clogging indicator responds.
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AMRF4 Replacing the filter elements
Replacing the filter elements
To change the filter elements, proceed as follows:
1. Switch the pump off. 2. Close the shut-off valves to the INLET and
OUTLET.
3. Completely unscrew the air-vent plug (x) in the cover with a size 6 mm Allen wrench.
4. Have a suitable container, approx. 120 liters, handy or guide the draining fluid back to the dirt tank.
Drain the filter housing by opening the drain ball valve of the contaminated side.
Close the drain ball valve once no more fluid escapes.
5. Have a suitable container, approx. 50 liters,
handy or guide the draining fluid back to the dirt tank.
Drain the filter housing by opening the drain ball valve of the clean side.
Close the drain ball valve once no more fluid escapes.
6. Loosen all toggle screws on the cover with a 24 mm box wrench and disengage them.
7. Remove the filter cover and place it on a clean
surface.
Observe the cover's weight of approx. 23 kg.
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AMRF4 Replacing the filter elements
8. Remove the element holding plate in the upwards direction.
9. Remove all filter elements and dispose of them in an environmentally friendly way.
10. Clean the inside of the filter housing of coarse dirt.
11. Prepare the new filter elements by moistening the O-ring on each element with the operating medium.
12. Insert the new elements into the element receptacle by applying pressure while slightly rotating the element.
Do not use excessive force or a hammer, etc.
13. g.
g ring for damage.
Lightly wet the O-ring on the cover with medium.
Clean the sealing surface on the filter housin
Check the housing sealinReplace it if necessary.
14. the filter elements with the element holding plate.Place the element holding plate on and center
15. Clean the sealing surface on the cover. 16. Place the cover centrally on the filter housing it.
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AMRF4 Replacing the filter elements
17. Engage all toggle screws.
18. Tighten the toggle screws with a 24 mm box
wrench crosswise with a maximum of 85 Nm force.
19. Open the locking features to the INLET and OUTLET.
Switch the pump on and fill the filter housing.
20. Unscrew the air bleed screw in the cover.
As soon as oil escapes, screw in the air bleed screw by hand and tighten it firmly.
21. The filter housing is ready for operation.
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AMRF4 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.
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AMRF4 Spare parts
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Item Qty Designation Part no.
101 1 O-ring for tank cover FKM 602369
113 1 Screw plug G ¼“ FKM 617037
124 2 Ball valve for draining G1“ 702406
125 2 Screw plug G1“ FKM 625359
600 1 Clogging indicator *
- 1 "IN" label 3341915
- 1 "OUT" label 3341917
- 2 "DRAIN" label 3207244
- - Filter elements *
* available on request
AMRF4 Disposing of the AMRF
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Disposing of the AMRF
Please dispose of the packaging material in an environmentally friendly manner.
After dismantling the unit and separating the various materials, dispose of the unit in an environmentally friendly manner.
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
E-Mail: [email protected]
Technical data
Technical data Number of filter elements 15 pcs.
Material of the housing 1.4301
Volume of housing in l ~ 147 liters
Operating pressure Maximum 10 bar
Material of seals FKM
Housing weight (empty) ~ 165 kg
Permissible operating temperature -10 … 90 °C / 14 … 194 °F
Storage temperature 5 … 30 °C / 41 … 86 °F
Hydraulic port (IN, OUT) DIN2576 DN80 PN10
AMRF4 Model Code
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Model Code
AMRF 4 E / 15 Q 40 10 F z 0
Filter type AMRF = Automotive Automotive MultiRheo Filter
Filter size 4 = Housing diameter ~ 355 mm
Filter housing material E = Stainless steel
Element quantity 15 = 15 Filter elements
Connection type Q = DIN DN80 PN 10
Element length 30 = 30“
40 = 40“
Pressure range 10 = 10 bar
Material of seals F = FKM
Clogging indicator D32 = Differential pressure gauge
(GW.0/-V-113)
Dz = Piping for retrofitting a differential pressure indicator
z = Without Clogging Indicator See HYDAC brochure for filter clogging indicators (D 7.050...)
Modification ID
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]