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Mayfran ConSep 2000-125HP Technical Documentation Manual

Tornos multideco / multialpha / multisigma
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Table of Contents

1
REVISION LIST ..........................................................................................................................................2
2
DECLARATION BY THE MANUFACTURER ............................................................................................3
3
GENERAL INFORMATION ........................................................................................................................3
3.1
Mayfran quality statement ..............................................................................................................3
3.2
Mayfran privacy statement .............................................................................................................3
4
UNPACKING AND TRANSPORT ..............................................................................................................4
4.1
Unpacking ......................................................................................................................................4
4.2
Transport........................................................................................................................................4
5
GENERAL WARNINGS AND SAFETY INSTRUCTIONS..........................................................................5
6
7
GENERAL PRODUCT / FUNCTION DESCRIPTION ................................................................................7
7.1
Use of the Consep 2000 ................................................................................................................7
7.2
Important instruction.......................................................................................................................7
7.3
When requesting information or ordering spare parts....................................................................7
7.4
The way in which the system works ...............................................................................................7
7.5
Indexing filter drum.........................................................................................................................8
7.5.1
Filter drum cleaning circuit .................................................................................................9
8
COMMISSIONING THE CONSEP 2000 SYSTEM...................................................................................10
9
STARTING UP THE CONSEP 2000 SYSTEM ........................................................................................11
9.1
Initial start-up procedure...............................................................................................................11
9.2
E-control box ................................................................................................................................11
9.3
How to start the system................................................................................................................11
9.3.1
Conveyors ........................................................................................................................11
9.3.2
Pumps..............................................................................................................................12
9.3.3
Pressure switches HP pumps..........................................................................................12
9.3.4
Level indicators additional coolant tank ...........................................................................12
9.3.5
Adjustement of automatic secondary system filter: .........................................................12
9.4
How to stop the system: ...............................................................................................................13
9.5
System malfunction......................................................................................................................13
10 PREVENTIVE MAINTENANCE ACTIONS...............................................................................................15
10.1
General issues .............................................................................................................................15
10.2
Maintenance actions mayfran components..................................................................................15
10.2.1
Driving unit steel belt conveyor / scraper conveyor........................................................15
10.2.2
Filter screen check.........................................................................................................16
10.2.3
Filter screen change procedure .....................................................................................16
10.2.4
Take-up adjustment steel belt conveyor / scraper conveyor .........................................17
10.2.5
Check items ...................................................................................................................18
11 FLOW DIAGRAM .....................................................................................................................................19
11.1
Flow diagram ConSep 2000-125 "L-Series".................................................................................19
11.2
Flow diagram ConSep 2000-125 "Regular" .................................................................................20
12 REPLACEMENT PARTS LISTS ..............................................................................................................21
12.1
Part list ConSep 2000-125 "L-Series" ..........................................................................................21
12.2
Part list ConSep 2000-125 "Regular" ...........................................................................................22
Rev. 0
Internet: www.mayfran.eu
E-mail: Info@mayfran-europe.com
ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma

TECHNICAL DOCUMENTATION

COMMISSIONING/ SERVICE/ MAINTENANCE
: (31) 45 5329 292
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 1

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  • Page 1 Part list ConSep 2000-125 “L-Series” ..................21 12.2 Part list ConSep 2000-125 “Regular” ...................22 Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 File name: Internet: www.mayfran.eu T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.

  • Page 2: Revision List

    Original release Eare Revision Date Description Name Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 File name: Internet: www.mayfran.eu T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev. 0_English.doc E-mail: Info@mayfran-europe.com Page: 2...

  • Page 3: Declaration By The Manufacturer

    Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 File name: Internet: www.mayfran.eu...

  • Page 4: Unpacking And Transport

    With forklift truck: - Transport only on the original wooden pallet. - Also secure equipment against falling or slipping. Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 File name: Internet: www.mayfran.eu T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.

  • Page 5: General Warnings And Safety Instructions

    Never remove covering materials while the unit is in use! • Never reach into the discharge opening! • Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 File name: Internet: www.mayfran.eu T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.

  • Page 6: General Instructions For Repair, Maintenance And Malfunctions

    If coming into contact with swarf: Wear protective clothing, protective shoes, and protective gloves! • Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 File name: Internet: www.mayfran.eu T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.

  • Page 7: General Product / Function Description

    This manual must be made available to the maintenance personal responsible for the ConSep 2000. The Mayfran guarantee will only apply if the instructions set out in this manual have been strictly adhered to. WHEN REQUESTING INFORMATION OR ORDERING SPARE PARTS Main spare components and wear components are listed on provided parts list! (See Chapter 12).

  • Page 8: Indexing Filter Drum

    Tornos MultiDECO / MultiAlpha / MultiSigma INDEXING FILTER DRUM The ConSep 2000-125HP unit features the latest Mayfran innovation on self-cleaning coolant filtration equipment. The indexing filter drum is positioned in the upward curve of the conveyor unit. The special drive mechanism utilizes the motion from the steel belt conveyor to create an indexing rotation of the filter drum.

  • Page 9: Filter Drum Cleaning Circuit

    Drum cleaning must be clearly visible on outside of the filter screen (see picture). Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 File name: Internet: www.mayfran.eu T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.

  • Page 10: Commissioning The Consep 2000 System

    During running of conveyor take care that the conveyor belt and/or the grippers are able to move freely without chafing anywhere. Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 File name: Internet: www.mayfran.eu...

  • Page 11: Starting Up The Consep 2000 System

    Tornos MultiDECO / MultiAlpha / MultiSigma STARTING UP THE CONSEP 2000 SYSTEM INITIAL START-UP PROCEDURE Position the Mayfran ConSep unit according to Tornos drawings supplied with Tornos documentation. Connect ConSep unit electrically. Connect hydraulic hoses of pumps according supplied documentation by Mayfran.

  • Page 12: Pumps

    Air inlet pressure to automatic secondary system filter should be set to 6 bar. For detailed information of secondary system filter: see separate supplied supplier documentation. Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 File name: Internet: www.mayfran.eu...

  • Page 13: How To Stop The System

    Turning the main switch counter clockwise will stop the Mayfran system. SYSTEM MALFUNCTION Below you will find a listing of possible faults according Mayfran electrical lay out. To resolve possible faults please also check supplier documentation of the components mounted on ConSep system.
  • Page 14 Tornos MultiDECO / MultiAlpha / MultiSigma Note 1: The item numbers in italic correspond with items on Mayfran flow diagram F74600.009.02. Note 2: With alarm class 1 (orange), the machine will not stop immediately; machine cycle will finish before stop.

  • Page 15: Preventive Maintenance Actions

    10.1 GENERAL ISSUES Provided that this MAYFRAN ConSep 2000 is properly maintained, it will last a long time with a minimum of wear. Please ensure that the belt and chain are lightly oiled at all times. Normally the belt should be oiled on a monthly basis.

  • Page 16: Filter Screen Check

    Filter retainer A Filter retainer B Filter frame unit Filter Fig. 1 Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 File name: Internet: www.mayfran.eu T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev. 0_English.doc E-mail: Info@mayfran-europe.com...

  • Page 17: Take-Up Adjustment Steel Belt Conveyor / Scraper Conveyor

    Otherwise the drive shaft will not be perpendicular to the direction of transport. When finished, re-mount drive cover and side panels of the drive cover. Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 File name: Internet: www.mayfran.eu T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.

  • Page 18: Check Items

    Back wash nozzles wear. Check visually. Replace. Next to above described items Mayfran also advises annual complete manual cleaning of ConSep 2000 system to remove small fines and debris from the various clean tank compartments and system components. Rev. 0 MAYFRAN INTERNATIONAL - P.B.

  • Page 19: Flow Diagram

    Tornos MultiDECO / MultiAlpha / MultiSigma FLOW DIAGRAM 11.1 FLOW DIAGRAM CONSEP 2000-125 “L-SERIES” Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 File name: Internet: www.mayfran.eu T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.

  • Page 20: Flow Diagram Consep 2000-125 "Regular

    ConSep 2000®-125HP Tornos MultiDECO / MultiAlpha / MultiSigma 11.2 FLOW DIAGRAM CONSEP 2000-125 “REGULAR” Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 File name: Internet: www.mayfran.eu T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.

  • Page 21: Replacement Parts Lists

    Tornos MultiDECO / MultiAlpha / MultiSigma REPLACEMENT PARTS LISTS 12.1 PART LIST CONSEP 2000-125 “L-SERIES” Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 File name: Internet: www.mayfran.eu T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.

  • Page 22: Part List Consep 2000-125 "Regular

    ConSep 2000®-125HP Tornos MultiDECO / MultiAlpha / MultiSigma 12.2 PART LIST CONSEP 2000-125 “REGULAR” Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 File name: Internet: www.mayfran.eu T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
  • Page 25 Part list for CONSEP2000II-125HP "L-Series" MAYFRAN-Order no. : 00M0000 Customer : Tornos Product : CONSEP2000II-125HP "L-Series" Machine : MultiDECO / MultiAlpha / MultiSigma Drawing no. : T74600.010.00_00 / F74600.010.00_00 Order no. : Pos.nr. MF-Article-Nr. Number Description Manufacturer Type / Drawingnr.
  • Page 26 Part list for CONSEP2000II-125HP "Regular" MAYFRAN-Order no. : 00M0000 Customer : Tornos Product : CONSEP2000II-125HP "Regular" Machine : MultiDECO / MultiAlpha / MultiSigma Drawing no. : T74600.011.00_00 / F74600.011.00_00 Order no. : Pos.nr. MF-Article-Nr. Number Description Manufacturer Type / Drawingnr.
  • Page 27 High Pressure Pumps 2006...
  • Page 28 The Brinkmann Screw Pump Series has been specifically designed for the machine tool industry, with a clear focus on high wear- resistance, long life expectancy and extremely high pump efficiencies. Each Brinkmann pump Our highly sophisticated reflects a tremendous modular design system amount of R&D work and allows us to fulfill your long term testing, in our...
  • Page 29 Content Page Technical Information 4 – 6 Electrical Questionnaire Models and Applications 8 – 9 High Pressure Pumps Screw spindles 10 – 11 BFS1, FFS1 / 50 Hz High pressure BFS2, FFS2 / 50 Hz 1.5 ... 25.5 l/min 10 ... 150 bar High Pressure Pumps Screw spindles 12 –...
  • Page 30 Technical Information Electrical Features CE Motors acc. to EN 60034 (VDE 0530) Motors of 7.5 kW Grade of protection IP55 Motor design available for -starting. Type of insulation Screw pumps must be started without back pressure when utilizing a -start-up mode.
  • Page 31 Technical Information Electrical / Hydraulic Features Set-up altitude and coolant temperature Viscogram The specified power ratings (P ) and operating values for the motors apply to operating mode S1 according to EN 60034-1 (continuous operation) at a frequenzy of 60 Hz, rated voltage, a cooling air tem- perature (KT) of max.
  • Page 32 Technical Information Electrical Features Technical motor data Three-phase induction motor 2 pole, thermal protection class F, grade of protection IP 55 Brinkmann motors Power Rated current Noise level Rated current Noise level max. max. 50 Hz / 60 Hz 2 pole 50 Hz 2 pole 60 Hz 380–420 V / 380–420 V...
  • Page 33 Application Questionnaire Please forward questionnaire via fax to +49 (0) 2392 / 5006 - 180 via e-mail to Kontakt@BrinkmannPumps.de Company ..........Date ..........Location ..........Contact partner ..........Telephone ..........Field of application type:grinding Materials: cast iron specific abrasion: tinder drilling brass diamond...
  • Page 34 Models and Applications for High Pressure Screw Pumps Applications Materials of construction Brinkmann screw pumps reach pressures of up to 150 bar by utilizing highly wear Types of fluid Pressure and resistant screw spindles and silicon carbide oils Suction Housing Cast iron spindle housings.
  • Page 35 Models and Applications for High Pressure Screw Pumps Subject to alteration...
  • Page 36 High Pressure Pumps BFS1, FFS1 / BFS2, FFS2 50 Hz Screw spindles 2-pole motor 4-pole motor rotation speed 2900 RPM rotation speed 1450 RPM Pressure Flow at viscosity Power Motor Motor Weight Flow at viscosity Power Motor Weight max. con- Brinkmann foot con-...
  • Page 37 Characteristics and dimensions BFS1, FFS1 / BFS2, FFS2 50 Hz Viscosity 20 mm²/s Viscosity 1 mm²/s Volumetric delivery l/min Volumetric delivery l/min L = Leakage hole S = Mounting plate, please find the cut-out of mounting hole on page 35. *) Dimensions for 4-pole standard motor upon request **) Dimensions for BFS2...
  • Page 38 High Pressure Pumps BFS2, FFS2 50 Hz Screw spindles 2-pole motor 4-pole motor rotation speed 2900 RPM rotation speed 1450 RPM Pressure Flow at viscosity Power Motor Motor Weight Flow at viscosity Power Motor Weight max. con- Brinkmann foot con- sumption immersion mounted...
  • Page 39 Characteristics and dimensions BFS2, FFS2 50 Hz Viscosity 20 mm²/s Viscosity 1 mm²/s Volumetric delivery l/min Volumetric delivery l/min L = Leakage hole S = Mounting plate, please find the cut-out of mounting hole on page 35. *) Dimensions for 4-pole standard motor upon request Motor 2 pole...
  • Page 40 High Pressure Pumps TFS3, FFS3 50 Hz Screw spindles 2-pole motor 4-pole motor rotation speed 2900 RPM rotation speed 1450 RPM Pressure Flow at viscosity Power Motor Weight Flow at viscosity Power Motor Weight max. con- con- sumption sumption 1mm²/s 20 mm²/s 1mm²/s 20 mm²/s...
  • Page 41 Characteristics and dimensions TFS3, FFS3 50 Hz Viscosity 20 mm²/s Viscosity 1 mm²/s Volumetric delivery l/min Volumetric delivery l/min L = Leakage hole S = Mounting plate, please find the cut-out of mounting hole on page 35. Motor Motor 2 pole 4 pole 1.1 / 1.5 15.0...
  • Page 42 High Pressure Pumps TFS4, FFS4 50 Hz Screw spindles 2-pole motor 4-pole motor rotation speed 2900 RPM rotation speed 1450 RPM Pressure Flow at viscosity Power Motor Weight Flow at viscosity Power Motor Weight max. con- con- sumption sumption 1mm²/s 20 mm²/s 1mm²/s 20 mm²/s...
  • Page 43 Characteristics and dimensions TFS4, FFS4 50 Hz Viscosity 20 mm²/s Viscosity 1 mm²/s Volumetric delivery l/min Volumetric delivery l/min L = Leakage hole S = Mounting plate, please find the cut-out of mounting hole on page 35. Motor Motor 2 pole 4 pole 15.0 2.2 / 3.0...
  • Page 44 High Pressure Pumps TFS5, FFS5 50 Hz Screw spindles 2-pole motor 4-pole motor rotation speed 2900 RPM rotation speed 1450 RPM Pressure Flow at viscosity Power Motor Weight Flow at viscosity Power Motor Weight max. con- con- sumption sumption 1mm²/s 20 mm²/s 1mm²/s 20 mm²/s...
  • Page 45 Characteristics and dimensions TFS5, FFS5 50 Hz Viscosity 20 mm²/s Viscosity 1 mm²/s Volumetric delivery l/min Volumetric delivery l/min L = Leakage hole S = Mounting plate, please find the cut-out of mounting hole on page 35. Motor Motor 2 pole 4 pole –...
  • Page 46 High Pressure Pumps BFS1, FFS1 / BFS2, FFS2 60 Hz Screw spindles 2-pole motor 4-pole motor rotation speed 3500 RPM rotation speed 1750 RPM Pressure Flow at viscosity Power Motor Motor Weight Flow at viscosity Power Motor Weight max. con- Brinkmann foot con-...
  • Page 47 Characteristics and dimensions BFS1, FFS1 / BFS2, FFS2 60 Hz Viscosity 20 mm²/s Viscosity 1 mm²/s Volumetric delivery l/min Volumetric delivery l/min L = Leakage hole S = Mounting plate, please find the cut-out of mounting hole on page 35. *) Dimensions for 4-pole standard motor upon request **) Dimensions for BFS2 Motor...
  • Page 48 High Pressure Pumps BFS2, FFS2 60 Hz Screw spindles 2-pole motor 4-pole motor rotation speed 3500 RPM rotation speed 1750 RPM Pressure Flow at viscosity Power Motor Motor Weight Flow at viscosity Power Motor Weight max. con- Brinkmann foot con- sumption immersion mounted...
  • Page 49 Characteristics and dimensions BFS2, FFS2 60 Hz Viscosity 20 mm²/s Viscosity 1 mm²/s Volumetric delivery l/min Volumetric delivery l/min L = Leakage hole S = Mounting plate, please find the cut-out of mounting hole on page 35. *) Dimensions for 4-pole standard motor upon request Motor 2 pole...
  • Page 50 High Pressure Pumps TFS3, FFS3 60 Hz Screw spindles 2-pole motor 4-pole motor rotation speed 3500 RPM rotation speed 1750 RPM Pressure Flow at viscosity Power Motor Weight Flow at viscosity Power Motor Weight max. con- con- sumption sumption 1mm²/s 20 mm²/s 1mm²/s 20 mm²/s...
  • Page 51 Characteristics and dimensions TFS3, FFS3 60 Hz Viscosity 20 mm²/s Viscosity 1 mm²/s Volumetric delivery l/min Volumetric delivery l/min L = Leakage hole S = Mounting plate, please find the cut-out of mounting hole on page 35. Motor Motor 2 pole 4 pole 2.55 1.3 / 1.75...
  • Page 52 High Pressure Pumps TFS4, FFS4 60 Hz Screw spindles 2-pole motor 4-pole motor rotation speed 3500 RPM rotation speed 1750 RPM Pressure Flow at viscosity Power Motor Weight Flow at viscosity Power Motor Weight max. con- con- sumption sumption 1mm²/s 20 mm²/s 1mm²/s 20 mm²/s...
  • Page 53 Characteristics and dimensions TFS4, FFS4 60 Hz Viscosity 20 mm²/s Viscosity 1 mm²/s Volumetric delivery l/min Volumetric delivery l/min L = Leakage hole S = Mounting plate, please find the cut-out of mounting hole on page 35. Motor Motor 2 pole 4 pole 1.75 / 2.55 1.3 / 1.75...
  • Page 54 High Pressure Pumps TFS5, FFS5 60 Hz Screw spindles 2-pole motor 4-pole motor rotation speed 3500 RPM rotation speed 1750 RPM Pressure Flow at viscosity Power Motor Weight Flow at viscosity Power Motor Weight max. con- con- sumption sumption 1mm²/s 20 mm²/s 1mm²/s 20 mm²/s...
  • Page 55 Characteristics and dimensions TFS5, FFS5 60 Hz Viscosity 20 mm²/s Viscosity 1 mm²/s Volumetric delivery l/min Volumetric delivery l/min L = Leakage hole S = Mounting plate, please find the cut-out of mounting hole on page 35. Motor Motor 2 pole 4 pole –...
  • Page 56 Accessories Non-adjustable Pressure Relief Valves Screw spindle pumps are positive displacement pumps which In order to avoid pressure spikes in the system a pressure relief always require the installation of a pressure relief valve in order valve which cushions against vibration is recommended. to prevent bursting.
  • Page 57 Accessories Adjustable Pressure Relief Valves Adjustable pressure relief valves allow for variable operating pressures anywhere between 5 - 120 bar. In order to prevent overloading of the motor, however, the maximum operating pressure may never exceed the highest allowable operating pressure for the specific pump and motor combination in use.

  • Page 58: Pressure Gauge

    Accessories Pressure gauge Pump system, fully assembled Series BFS1 and BFS2, non-adjustable pressure relief valve: Screw pump with mounting plate, integrated connection block and piping fully assembled. The non-adjustable pressure relief valve is integrated into the connection block. Pressure Type p (bar) M 60 0 –...
  • Page 59 Accessories Pump system, fully assembled Series BFS1 and BFS2, adjustable pressure relief valve: Series TFS3, non adjustable pressure relief valve: Screw pump with mounting plate, integrated connection Screw pump with mounting plate, integrated connection block and piping fully assembled. block and piping fully assembled. The non-adjustable pressure relief valve is integrated into The non-adjustable pressure relief valve is integrated into the connection block.
  • Page 60 Accessories Pump system, fully assembled Series TFS3, adjustable pressure relief valve: Series TFS4 and TFS5, adjustable pressure relief valve Screw pump with mounting plate, integrated connection (pneumatically operated): block and piping fully assembled. Screw pump with mounting plate, adjustable pressure The non-adjustable pressure relief valve is integrated into relief valve (pneumatically operated) and piping fully the connection block.
  • Page 61 Technical information Execution G4 Cut-out of mounting hole BFS1/BFS2 TFS1/TFS2 Ø 146 Ø 121 TFS3/TFS4 TFS5 Ø 185 Ø 205 Ø 161 Ø 176 G1/8" BFS/FFS 1,2 G1/4" TFS/FFS 3,4,5 All edges deburred! Pressureless drainage return into the tank General tolerances ISO 2768-m Immersion Pumps Semi-open impellers TB16 ...
  • Page 62 BRINKMANN PUMPEN D-58791 Werdohl Operating instructions BRINKMANN-Scew pump Type BFS / TFS Description of product and function Scope Pumping of liquids under back pressure Range of application – Screw pumps are designed for pumping liquid lubricants and other liquids – Used in all fields in which high pressures and consistent pumping capacity is required (e.g.
  • Page 63 BRINKMANN PUMPEN D-58791 Werdohl BRINKMANN-Scew pumpType BFS / TFS Prior to initial operation Pipework • Connect suction line, pressure line and overpressure relief line as shown in figure Direction of rotation • Rotation of the motor must correspond to the indicating arrow of the pump •...
  • Page 64 BRINKMANN PUMPEN D-58791 Werdohl BRINKMANN-Scew pump Type BFS / TFS Switching off • Switch off motor • Close gate valve in the pressure line (does not apply for built-in check valve) Þ Þ Þ Þ - Ensure that the pump slows down to a stop evenly and smoothly - For longer downtimes, dismantle and preserve pump Maintenance Þ...
  • Page 65 BE2886 Operating Instructions Brinkmann Immersions pumps of the series TGL331... 503 Contents 1 General..............1 6 Start up / Shut down ..........2 2 Safety ..............2 7 Servicing and Maintenance ........3 3 Transport and storage ........... 2 8 Trouble shooter’s guide .........3 4 Description of product and accessories ....
  • Page 66 4 Description of product and accessories Pumps of the series TGL331...503 are multi-stage rotary pumps. The impellers are fixed on the driving shaft extension. Pump and motor form a compact and space-saving unit. Pumps of this type are fitted out with semi-open impellers and a suction screw.
  • Page 67 The temperature of the medium is not allowed to be higher than 80 ° C ! The pumps are for continuous running against a closed sliding valve not suitable ( plan bypass ). The particle-size in the medium is not allowed to be bigger than 8 mm ATTENTION for TGL331...333 and 12 mm for TGL501...503.
  • Page 68 9 Spare part list for the immersion pumps of the series TGL331 ... 503 Item Description Stator with terminal board End shield Terminal box Fan cover Ball bearing DIN 625 Ball bearing DIN 625 Gasket Retaining ring Thread rolling screw DIN 7500 up 1,5 kW Slotted cheese head screw...
  • Page 69 BE2805 Operating Instructions Brinkmann Immersions pumps of the series SGL332... 503 Contents 6 Start up / Shut down ..........2 1 General..............1 2 Safety ..............1 7 Servicing and Maintenance ........3 3 Transport and storage ........... 1 8 Trouble shooter’s guide .........3 4 Description of product and accessories ....
  • Page 70 Check the terminal links according to the following wiring diagram. Star connection Delta connection 3 x 400 V, 50 Hz 3 x 230 V, 50 Hz resp. 380-420 V, 50 Hz resp. 220-240 V, 50 Hz Work on the electrical equipment must only be carried out by a qualified electrician.
  • Page 71 The temperature of the medium is not allowed to be higher than 80 °C ! The pumps are for continuous running against a closed slid- ing valve not suitable ( plan bypass ). The particle-size in the medium is not allowed to be big- ATTENTION ger than 8 mm for SGL332...333 and 12 mm for SGL502...503.
  • Page 72 9 Spare part list for the immersion pumps of the series SGL332 ... 503 Item Description Stator with terminal board Motor flange End shield Terminal box Fan cover Ball bearing DIN 625 Ball bearing DIN 625 Gasket Retaining ring Thread rolling screw DIN 7500 Slotted cheese head screw DIN 84...
  • Page 73 10 Repair Instructions / Replacing shaft clamp and shaft 1 = Shaft clamp 2 = Insert shaft 3 = Motor shaft Dismantling the insert shaft Disconnect the immersion pump from the mains both electrically and mechanically. Set the pump down on the fan cover. Dismantle the pump unit and the pump body. Loosen the screws on the shaft clamp (1) one after the other.
  • Page 75 BE2610 Operating Instructions Brinkmann Immersions pumps of the series STA/SAL402 ... 609 Contents 1 General..............1 6 Start up / Shut down ..........3 2 Safety ..............2 7 Servicing and Maintenance ........4 3 Transport and storage ........... 2 8 Trouble shooter’s guide .........4 4 Description of product and accessories ....
  • Page 76 Max. del. pressure Max. del. volume Depth of immer- Weight / Power sion / STA Type Type bar / spec. weight 1 l/min h mm g kg STA407 / 420 SAL407 / 440 STA409 / 520 SAL409 / 540 STA602 / 200 SAL602 / 220 1000 1020...
  • Page 77 2 Safety See appendix A. 3 Transport and storage Protect the pump against damage when transporting. Store pump in dry and protected areas and protect it against penetration of foreign bodies. 4 Description of product and accessories Pumps of the series STA/SAL402...609 are multi-stage rotary pumps. The impellers are fixed on the driving shaft exten- sion.
  • Page 78 The temperature of the medium is not allowed to be higher than 80 °C! The pumps are for continuous running against a closed sliding valve not suitable ( plan bypass ). The particle-size in the medium is not allowed to be bigger than 8 mm for STA/SAL402...409 and 12 mm for STA/SAL602...609! ATTENTION Switching-on frequency: Motors less 3 kW...
  • Page 79 9 Spare part list for the immersion pumps of the series STA/SAL402 ... 609 Item Description Stator with terminal board Motor flange End shield Terminal box up to 5,5 kW Terminal box frame up 7,5 kW Terminal box cover up 7,5 kW Fan cover Ball bearing DIN 625...
  • Page 80 Repair Instructions / Replacing shaft clamps and shafts 1 = Shaft clamp 2 = Insert / extension shaft 3 = Motor shaft / Insert shaft Dismantling the insert shaft or extension shaft Disconnect the submergible pump from the mains both electrically and mechanically. Set the pump down on the fan cover.
  • Page 81 Quick Suctioning Immersion Pumps (S)TAL601...609 Axial/semi-open impellers Vol. del. Height Depth Weight Power Voltage Fre- Rated Speed TAL601...604 at manom. of im- quency current del. head mersion Type l/min. /m H mm h mm TAL601/150 400/5 220-240 50 2700 15.5 380-420 50 2700 16.5...
  • Page 82 Quick suctioning immersion pumps Applications Construction equipped with the patented "BRINKMANN`s Types of fluid Pump body cast iron Suction De-aeration System" are excellently water Cover cast iron suited to pumping extremely inflated fluids coolants Impeller axial cast steel (emulsions resp. cooling/cutting oils) as they cooling/cutting oils Impeller radial brass...

  • Page 83: Safety Instructions

    Appendix A Safety instructions 2.4 Compliance with regulations pertaining to 2.0 General safety at work This operating manual gives basic instructions which are When operating the pump, the safety instructions con- to be observed during installation, operation and mainte- tained in this manual, the relevant national accident nance of the pump.
  • Page 84 Appendix B Operating Instructions Mechanical and Electrical Special Designs: 1) Identification of Special Designs Special mechanical and electrical designs are marked on the pump label by an additional letter or number. When ordering a pump or a spare part it is important to use the complete pump number. Examples for special designs: pump inlet cover and impeller in cast iron.
  • Page 85 REF 9.360 page 01 DIRECTLY OPERATED PRESSURE RELIEF VALVE SIZE Types VME 06-07-08 Types VME 06-07-08 NOMINAL PORT SIZE l/min MAX FLOW RATE US gpm 10.5 MAX PRESSURE 4500 4500 4500 MAX TIGHTENING TORQUE CARTRIDGE ONLY 0.13 0.20 0.35 WEIGHT WITH 0.33 0.47...
  • Page 86 REF 9.360 page 02 DIMENSIONS (mm) NORMALIZED CAVITIES VME 06 VME 07 VME 08 DIMENSIONS (mm) STANDARD HOUSING FOR VME 06 Version DG Version LG DIMENSIONS (mm) STANDARD HOUSING FOR VME 07 Version DG Version LG...
  • Page 87 REF 9.360 page 03 DIMENSIONS (mm) STANDARD HOUSING FOR VME 08 Version DG Version LG CHARACTERISTIC OPERATING CURVES Measurements effected at 20°C ambient temperature with mineral oil having viscosity of 26 cSt at 50°C. With housing DG.
  • Page 88 REF 9.360 page 04 EXAMPLE OF DESIGNATION VME 06 VME 06 / EN - 2 - 00 - V VME 06 / EN - 2 - 00 - V TYPE SEALS V = Viton seals SIZE Ignore for normal seals TYPE OF ADJUSTMENT 00 = Cartridge only EN = External screw...
  • Page 89 KA 213F/00/a6/07.03 52019485 liquiphant FTL 20 Füllstandgrenzschalter für Flüssigkeiten • universell einsetzbar • wartungsfrei Betriebsanleitung Level limit switch for liquids • universally applicable • maintenance-free Operation Manual Détecteur de niveau pour liquides • utilisation universelle • sans maintenance Mise en service Interruptor de límite de nivel para fluidos •...
  • Page 90 Contents What the Liquiphant can do Here you can find information on: • Applications • Benefits and Functional description • Installation examples and Application instructions • Operating modes for variants AC and DC-PNP • Product variants and Ordering Code • Certificates and Accessories Technical data Here you will find connection data, operating...

  • Page 91: Functional Description

    What the Liquiphant can do Applications The Liquiphant FTL 20 is a level limit switch for all kinds of fluids and is used in tanks, containers and pipelines. It is used in cleaning and filtering systems and coolant and lubricant tanks as an overspill protection or as a pump protector.
  • Page 92 Installation examples The Liquiphant FTL 20 can be installed in any position in a tank or pipe. The formation of foam does not impair its function. Example c: Overspill protection or top level detection Example d: Dry running protection for pumps Example e: Lower level detection or dry running protection Application instructions...
  • Page 93 CORRECT WRONG Operating modes for variants AC and DC-PNP The FTL 20 can be connected in two operating modes. Depending on the operating mode selected (MAX or MIN safety), the FTL 20 will switch off safely in the event of a fault, (e.g. if the power supply line is interrupted).
  • Page 94 Product variants and Ordering Code Liquiphant FTL 20 Certificate (see below) For non-hazardous areas, WHG, Leckage-detedtion CSA General Purpose, CSA US Special version Process connection, material Thread ISO 228, G 1/2 A, 316L Thread ISO 228, G 3/4 A, 316L Thread ISO 228, G 1 A, 316L Thread ANSI,...
  • Page 95 Certificates The general authorisation by the board of surveyors must be obtained for the site of installation of the FTL 20. The Technical Description and Certificates can be obtained from: • http://www.endress.com/ftl20 The Liquiphant meets the statutory requirements of EC directives. Endress+Hauser confirms the successful testing of the device by affexing the CE mark.
  • Page 96 Technical data Variant AC (alternating current) Supply voltage 19 ... 253 V AC, 50/60 Hz Connectable load Max. 250 mA (auto. load verification on connection) Supply current Max. 3.8 mA Connector Valve plug Variant DC-PNP (direct current) Supply voltage 10 ... 35 V DC Power supply Safety extra-low voltage Class 2 circuit (North America)
  • Page 97 EMC AC and DC-PNP Interference emission as per EN 61326; Equipment Class B interference immunity as per EN 61326; Appendix A (industrial application) and NAMUR Recommendation NE 21 (EMC) EMC AS-i EN 50295 Storage temperature –40 ... +85 °C Output, general Switch time Approx.
  • Page 98 Dimensions (150 °C) in mm Connector M12x1 Valve plug ø40 ø31.5 ø31.5 32 AF 32 AF 3.5 * 3.5 * ø17.1 ø17.1 Switch point for vertical installation Switch point for horizontal installation; level rises in the direction of the arrow Switch points at: density 1 / 23 °C / 0 bar...
  • Page 99 Dimensions (100 °C) in mm Connector M12x1 Valve plug ø40 ø31.5 ø31.5 32 AF 32 AF ø17.1 ø17.1 Switch point for vertical installation Switch point for horizontal installation; level rises in the direction of the arrow Switch points at: density 1 / 23 °C / 0 bar Endress + Hauser...

  • Page 100: General Safety Instructions

    Safety Intended application The FTL 20 may only be used as a level limit switch for fluids and only in non-hazardous areas. It must be installed in a fixed position in a tank or pipe wall. General safety instructions Improper use may cause dangerous situations to emanate from the FTL 20.
  • Page 101 Installation and connection Mounting and adjusting ¾ Observe the general safety instructions Caution! Damage to the device by improper handling! ¾ Do not bend, shorten or change the shape of tuning fork. ¾ Only tighten using open-ended hex wrench or socket wrench. ¾...

  • Page 102: Electrical Connection

    Electrical connection Requirements: Operating mode (MIN or MAX) is defined (see page 23). ¾ Comply with the safety instructions (see page 30). ¾ Comply with cable specifications for the present connector (see page 27). ¾ Read the nameplate to determine what variant the FTL 20 is: variant DC-PNP, variant AC or AS-i-Bus.
  • Page 103 Valve plug Operating mode Operating mode – – 0,5A 0,5A L– L– (Ground) (Ground) Connect variant AC (alternating current) Operating mode Operating mode > 19V > 19V 0,5A 0,5A (Ground) (Ground) Endress + Hauser...
  • Page 104 Connect AS-i-Bus AS-i + 1: BN 3: BU AS-i – Programming instruction for the AS-i AS-i-Profile: S-3.A.1 The address is defaulted to 0 (HEX). It is changeable via the bus master or programming unit. Data bit: D0:1 Sensor covered D1:1 State = OK D0:0 Sensor free D1:0 State = error D2 and D3 are not used.
  • Page 105 Light signals and faults The LED display is on the connection side of the FTL 20. The green light always comes on in service. Variants AC and DC-PNP with valve plug Light signal State/Action Red light comes Operating mode MAX (overspill protection): Sensor immersed in fluid.
  • Page 106 Cleaning and disposal Cleaning Caution! Do not damage device by knocks and bending! ¾ Only clean fork with wire brush. ¾ Never use a hammer or similar tools for cleaning. ¾ Remove any build-ups on tuning fork. Disposal ¾ Dispose of FTL 20 and test magnet according to local regulations.
  • Page 107 Endress + Hauser...
  • Page 108 Bestellung ¾ Geben Sie beim Endress+Hauser Sales Center Ihren Bestellcode an (siehe Seite 6). Ordering ¾ Specify your Ordering Code to the Endress+Hauser Sales Centre (see page 24). Commande ¾ Indiquer le code de commande à votre Sales Center Endress+Hauser (voir page 42). Pedido ¾...
  • Page 109 Level limit switch Technical Information TI 364F/00/en liquiphant T FTL 20 Level limit switch for liquids Application Your benefits The Liquiphant FTL 20 is a level limit • Operational safety, reliability and switch for all kinds of fluids and is used in universal applicability through use of tanks, containers and pipelines.
  • Page 110 Liquiphant T FTL 20 Table of contents Function and system design ....3 Mechanical construction ....10 Measuring principle .
  • Page 111 Liquiphant T FTL 20 Function and system design Measuring principle The tuning fork of the FTL 20 is brought to its resonance frequency by means of a piezoelectric drive. If the tuning fork is covered by liquid, this frequency changes. The electronics of the FTL 20 monitor the resonance frequency and indicate whether the tuning fork is freely vibrating or is covered by liquid.
  • Page 112 Liquiphant T FTL 20 Input Measured variable Density Measuring range > 0.7 g/cm other density settings on request, e.g. 0.5 g/cm Output Switching outputs DC-PNP valve DC-PNP M12x1 AC 2-wire AS-i connector Function Positive voltage signal at the switch output of the Switching the power Switching the electronics (PNP)
  • Page 113 Liquiphant T FTL 20 Power supply Cable entry min. 40 mm L00-FTL20xxx-04-05-xx-xx-001 Pg 11 / ½ NPT M 12x1 * QUICKON Plastic * Accessories 4x0.34 M12 elbowed (order number: 52010285) Electrical connection Variant DC-PNP (direct current) M12x1 connector Voltage source: shock-protected voltage or Class 2 circuit (North America) Suitable for use in non-equivalent operation: When both outputs are connected, the MIN and MAX outputs take on opposite states in trouble- free operation.
  • Page 114 Liquiphant T FTL 20 Variant DC-PNP (direct current) valve connector Operating mode MAX (NC contact) Operating mode MIN (NO contact) L00-FTL20xxx-04-05-xx-xx-005 L00-FTL20xxx-04-05-xx-xx-004 – – 0.5 A 0.5 A L– L– (Ground) (Ground) L00-FTL20xxx-04-05-xx-en-003 L00-FTL20xxx-04-05-xx-en-004 Variant AC (alternating current) valve connector Operating mode MAX Operating mode MIN L00-FTL20xxx-04-05-xx-xx-007...
  • Page 115 Liquiphant T FTL 20 Connect AS-i bus AS-i + 1: BN 3: BU AS-i – L00-FTL20xxx-04-05-xx-xx-008 Programming instructions for the AS-i AS-i profile: S-3.A.1 The address is defaulted to 0 (HEX). It is changeable via the bus master or programming unit. Data bit: D0:1 Sensor covered D1:1 Status = O.K.
  • Page 116 Liquiphant T FTL 20 Performance characteristics Switching delay 0.5 s when covering 1.0 s when becoming free other switching time on request Reference operating Ambient temperature: 23 °C conditions Process pressure: 1 bar Medium: water Medium density: 1 Medium temperature: 23 °C Installation from above /vertical Density setting: >...
  • Page 117 Liquiphant T FTL 20 Connecting cable Up to 1000 m with AC/DC-PNP, AS-i to IEC 62 026-2 Operating conditions: Environment Ambient temperature –40...+70 °C range –25...+70 °C (AS-i) • Ambient temperature Derating from 90.0 °C process temperature: Reduction to max. 50.0 °C ambient •...
  • Page 118 Liquiphant T FTL 20 Mechanical construction Design, dimensions of the Valve connector M12x1 QUICKON 150 °C variant ø40 ø40 ø31.5 ø31.5 ø31.5 32 AF 32 AF 32 AF ø17.1 ø17.1 ø17.1 L00-FTL20xxx-06-05-xx-en-001 *1 Switch point with vertical installation *2 Switch point with horizontal installation; the level increases in the direction of the arrow Switch points at: density 1 / 23 °C / 0 bar Endress + Hauser...
  • Page 119 Liquiphant T FTL 20 Design, dimensions of the M12x1 Valve connector 100 °C variant QUICKON ø40 ø40 ø31.5 ø31.5 ø31.5 32 AF 32 AF 32 AF ø17.1 ø17.1 ø17.1 L00-FTL20xxx-06-05-xx-en-002 *1 Switch point with vertical installation *2 Switch point with horizontal installation; the level increases in the direction of the arrow Switch points at: density 1 / 23 °C / 0 bar Process connections Process connection /...
  • Page 120 Liquiphant T FTL 20 Process connection / Accessories Pressure Dimensions (optional) Temperature G 1 A max. 40 bar DIN ISO 228/l max. 150 °C 66.5 (version 150 °C) 22.7 18.5 L00-FTL20xxx-06-05-xx-en-010 ½ NPT max. 40 bar ANSI B 1.20.1 max. 150 °C R ½...
  • Page 121 Liquiphant T FTL 20 Human interface Function test with Variants AC and DC-PNP: test magnet On testing, the current state of the electronic switch is reversed. Variant AS-Interface: On testing, D0 is inverted. Performing test Hold the test magnet against the mark on the nameplate: L00-FTL20xxx-19-05-xx-xx-001 The switching state changes.
  • Page 122 Liquiphant T FTL 20 Variant AS-interface and DC-PNP with M12x1 circular connector PPSU L00-FTL20Hxx-07-05-xx-xx-002 Green light (gn) lighting: FTL 20 is connected to the power supply and is operational. Yellow light (ye) lighting: Sensor is immersed in liquid. Red light (rd) lighting with AS-interface: Error: Address 0 set or communication error.

  • Page 123: Ordering Information

    Liquiphant T FTL 20 Certificates and approvals CE approval The device is in conformity with the statutory requirements of the EC Directives. Endress+Hauser confirms successful testing of the device by affixing the CE mark. Sanitary compatibility EHEDG (see process connections, Page 11), Approval number: 3119/03/0445 Overfill protection WRL and leakage...
  • Page 124 Liquiphant T FTL 20 Accessories Socket wrench Order number: 52010156 Socket wrench AF 32 L00-FTL20xxx-00-05-xx-en-001 Welding boss G ¾ Order number: 52018765 max. 25 bar 26,1 –0,2 max. 150 °C • For flush-mounted installation and sealing max. 40 bar • Sensor cannot be aligned max.
  • Page 125 Liquiphant T FTL 20 Endress + Hauser...
  • Page 126 Liquiphant T FTL 20 Endress + Hauser...
  • Page 127 Liquiphant T FTL 20 Endress + Hauser...
  • Page 128 Liquiphant T FTL 20 Endress Hauser GmbH+Co. Instruments International P.O. Box 2222 D-79574 Weil am Rhein Germany Tel. (07621) 975-02 Tx 773926 Fax (07621) 975 345 e-mail: info@ii.endress.com Internet: http://www.endress.com 11.01 TI 364F/00/en/11.03 SL/FM+SGML6.0 ProMoDo...
  • Page 134 ® Operating instructions AutoFilt English Postfach 1667 66516 Neunkirchen - Germany Industriegebiet Grube König Am Wrangelflöz 1 66538 Neunkirchen - Germany ++49 (0) 68 21 / 86 90 – 0 ++49 (0) 68 21 / 86 90 – 200 E-mail: prozess-technik@hydac.com Internet: www.hydac.com All rights reserved.
  • Page 135 ® Operating instructions AutoFilt English CONTENTS SAFETY ......................7 1.1 Basic safety information ....................7 1.2 Basic safety information ....................6 1.3 Appropriate use ......................8 1.4 Potential hazards in handling the back-flushing filter - AutoFilt RF4 ......8 1.5 Obligations of the operator and operating staff ............8 1.6 Action in an emergency ....................9 1.7 Service and maintenance, troubleshooting ..............9 1.8 Electrical hazards ......................9...
  • Page 136 ® Operating instructions AutoFilt English USING THE BACK-FLUSHING FILTER ............29 6.1 Operating and monitoring elements................25 6.2 Commissioning the back-flushing filter..............29 60.2.1 Setting the operating parameters................26 60.2.2 Decommissioning the back-flushing filter..............30 6.3 Decommissioning the RF4 for longer downtimes............31 MAINTENANCE OF THE BACK-FLUSHING FILTER........
  • Page 137 ® Operating instructions AutoFilt English LIST OF ILLUSTRATIONS FIGURE 1: FUNCTION PRINCIPLE OF THE BACK-FLUSHING FILTER............11 FIGURE 2: CONSTRUCTION OF THE BACK-FLUSHING FILTER:...............13 FIGURE 3: INSTALLATION OF RF4-1 (6 BAR) WITH LATERAL VALVE............18 FIGURE 4: INSTALLATION OF RF4-1 (6 BAR) WITH COAXIAL VALVE............19 FIGURE 5: INSTALLATION OF RF4-2 (6 BAR) WITH LATERAL VALVE............20 FIGURE 6: INSTALLATION OF RF4-2 ( 6 BAR) WITH COAXIAL VALVE............21 FIGURE 7: INSTALLATION OF RF4-1 (16 BAR).....................22...
  • Page 138 ® Operating instructions AutoFilt English TABLE 16: TECHNICAL SPECIFICATIONS - ACTUATOR................43 TABLE 17: TECHNICAL SPECIFICATIONS – INDUCTIVE PROXIMITY SWITCH........44 TABLE 18: TECHNICAL SPECIFICATIONS - DIFFERENTIAL PRESSURE SWITCH........47 TABLE 19: TECHNICAL SPECIFICATIONS – BACK-FLUSHING VALVE............50 DOCUMENTS SUPPLIED The following documents form part of this Operating Manual: 1.
  • Page 139 ® Operating instructions AutoFilt English 1 SAFETY 1.1 Basic safety information The safe handling and smooth operation of the filter cannot be guaranteed unless the basic safety information and safety regulations are fully understood and complied with. Always keep these Operating and Maintenance Instructions in the immediate vicinity of the back-flushing filter.
  • Page 140 ® Operating instructions AutoFilt English 1.3 Appropriate use The back-flushing filter - AutoFilt RF4 – is designed exclusively for the filtration of low viscosity fluids. The back-flushing filter is designed exclusively for the filtration of fluids, provided their temperature does not exceed the boiling point at atmospheric pressure. •...
  • Page 141 ® Operating instructions AutoFilt English 1.6 Action in an emergency In an emergency, turn the main switch off immediately and / or immediately shut off the compressed air supply to the back-flushing filter. Close the inlet and outlet lines of the back-flushing filter. 1.7 Service and maintenance, troubleshooting Ensure that the specified maintenance and inspection work is carried out at the required times.
  • Page 142 ® Operating instructions AutoFilt English 2 TRANSPORT AND STORAGE 2.1 Transport The back-flushing filter is supplied in a box or in a wooden crate. RF4-1 (6bar) RF4-2 (6 bar) Size Standard with G 1“ connection G1 1/2“ Approx. empty weight in kg 13 kg 32 kg Shipping weight in kg...
  • Page 143 ® Operating instructions AutoFilt English 3 TECHNICAL DESCRIPTION OF THE BACK-FLUSHING FILTER The AutoFilt RF4 back-flushing filter is a fully automatic self-cleaning filter designed to extract particles from low-viscosity fluids. When the set operating parameters are exceeded, the back-flushing filter automatically initiates regeneration (back-flushing) of the contaminated filter elements.
  • Page 144 ® Operating instructions AutoFilt English To trigger automatic back-flushing Back-flushing is triggered automatically: • When the pre-set differential pressure point is exceeded. As soon as back-flushing has been triggered, the filter starts to regenerate the filter elements. Back-flushing of the filter elements – back-flushing cycle •...
  • Page 145 ® Operating instructions AutoFilt English 3.3 Construction of the back-flushing filter Figure 2: Construction of the back-flushing filter: Vent screw Actuator Filter bowl Quick release band clamp Quick release bolt Outlet Differential pressure switch Outlet – back-flushing line Drain plug Back-flushing valve Inlet Leakage hole...
  • Page 146 ® Operating instructions AutoFilt English 3.4 Description of the filter components The drive unit (item 8) is located on the lower part (or head) of the filter, as configured in Figure 2, and rotates the filter elements one after another above the back-flushing line when back-flushing is triggered.
  • Page 147 ® Operating instructions AutoFilt English 4 DESCRIPTION OF THE MAIN COMPONENTS 4.1 Filter elements Slotted-tube elements in stainless steel are used. 4.2 Actuator Description The actuator rotates the element plate with the filter elements inside the filter during back-flushing. For general technical specifications, please see Actuator Section in the Appendix.
  • Page 148 ® Operating instructions AutoFilt English 4.4 Differential pressure switch The differential pressure switch compares the pressure drop between the contaminated and clean sides with the pre-set desired level. Differential pressure trigger for back-flushing Factory setting 0.5 bar This value should only be altered after consultation with HYDAC Process Technology! The differential pressure trigger point for back-flushing can be set on the knob of the pressure gauge (optional) to between 0.1 and 1 bar.
  • Page 149 ® Operating instructions AutoFilt English 4.5 Description of the control The control ensures optimum functioning of the Automatic Back-Flushing Filter RF4. It controls the actuator and the back-flushing valve and operates in response to the differential pressure switch. For general technical specifications, please see Control Section in the Appendix.
  • Page 150 ® Operating instructions AutoFilt English 5 INSTALLATION – ASSEMBLY AND CONNECTION 5.1 Installation of back-flushing filter Figure 3: Installation of RF4-1 (6 bar) with lateral valve BA RF4-Standard-deutsch/ englisch/ französisch 01/2007 HYDAC-Document: 03191177f Page 18...
  • Page 151 ® Operating instructions AutoFilt English Figure 4: Installation of RF4-1 (6 bar) with coaxial valve Connections: Inlet: ISO 8434-1-SDS-L28xG1 • Outlet: ISO 8434-1-SDS-L28xG1 • Back-flushing line: G1/2“ • Operating weight: 16 kg • Filter elements: • BA RF4-Standard-deutsch/ englisch/ französisch 01/2007 HYDAC-Document: 03191177f Page 19...
  • Page 152 ® Operating instructions AutoFilt English Figure 5: Installation of RF4-2 (6 bar) with lateral valve BA RF4-Standard-deutsch/ englisch/ französisch 01/2007 HYDAC-Document: 03191177f Page 20...
  • Page 153 ® Operating instructions AutoFilt English Figure 6: Installation of RF4-2 ( 6 bar) with coaxial valve Connections: Inlet: ISO 8434-1-SPS-L42xG1½” • Outlet: ISO 8434-1-SPS-L42xG1½” • Back-flushing line: Coaxial valve = G ¾“ ; Lateral valve = G ½“ • Operating weight: 36 kg •...
  • Page 154 ® Operating instructions AutoFilt English Figure 7: Installation of RF4-1 (16 bar) Connections: Inlet: G 1” • Outlet: G1“ • Back-flushing line: G ½“ • Operating weight: 17,5 kg • Filter elements: • BA RF4-Standard-deutsch/ englisch/ französisch 01/2007 HYDAC-Document: 03191177f Page 22...
  • Page 155 ® Operating instructions AutoFilt English Figure 8: Installation of RF4-2 (16 bar) Connections: Inlet: G1½” • Outlet: G1½” • Back-flushing line: Coaxial valve = G ¾“ ; Lateral valve = G ½“ • Operating weight: 63 kg • Filter elements: •...
  • Page 156 ® Operating instructions AutoFilt English Figure 9: Installation of RF4- (16 bar) electrical version Connections: Inlet: G1” • Outlet: G1” • Back-flushing line: G ½“ • Operating weight: 17,5 kg • Filter elements: • BA RF4-Standard-deutsch/ englisch/ französisch 01/2007 HYDAC-Document: 03191177f Page 24...
  • Page 157 ® Operating instructions AutoFilt English The filter can be installed either with the bowl at the top or underneath. The back-flushing filter is supplied complete with all necessary connections. The installation site must level and dry. Max. relative humidity: 80% If the back-flushing filter is operated at temperatures between 65°...
  • Page 158 ® Operating instructions AutoFilt English 5.2 Mounting Figure 10: Installation circuit diagram of the back-flushing filter The back-flushing filter must not be used as a pipe support. Ensure that the filter is flexibly mounted so that pipe forces are not transferred to the filter.
  • Page 159 ® Operating instructions AutoFilt English Inlet and outlet When connecting the lines, please observe the stipulated direction of flow. The inlet and outlet are marked with corresponding labels. To maintain the flow, even during any maintenance work, it is advisable to provide a bypass line with suitable shut-off valves.
  • Page 160 ® Operating instructions AutoFilt English 5.3 Connecting the power supply - EPT Voltages present in the electrical control box and in the mains supply are life- threatening. Opening the control box and all work on the electrical equipment of the filter must only be carried out by authorised personnel (qualified electricians).
  • Page 161 ® Operating instructions AutoFilt English 6 USING THE BACK-FLUSHING FILTER 6.1 Operating and monitoring elements Operating element Function Switches off the power supply to the back-flushing Main switch filter (provided by customer) Differential pressure switch Sets the differential pressure trigger point of the back-flushing cycle (optional).
  • Page 162 ® Operating instructions AutoFilt English 6.2.1 Setting the operating parameters You can set the following parameters on the back-flushing filter: - Differential pressure trigger point (optional), see Section 4.4 6.2.2 Decommissioning the back-flushing filter 1. Once the back-flushing cycle has been completed, close the outlet and inlet lines.
  • Page 163 ® Operating instructions AutoFilt English 6.3 Decommissioning the RF4 for longer downtimes To decommission the back-flushing filter, see Section 6.2. To remove the filter elements, see Section 7.4.1 Clean the filter elements using a high pressure cleaner and check them for damage. Replace any damaged filter elements with new ones. Check the element seals and replace any damaged seals.
  • Page 164 ® Operating instructions AutoFilt English 7 MAINTENANCE OF THE BACK-FLUSHING FILTER 7.1 Inspection by the operating staff Part Action Frequency Back-flushing filter Check for any external Monthly damage Vent back-flushing filter, On a regular basis, to prevent see also Section 6.2 formation of an air cushion in the filter housing Table 5:...
  • Page 165 ® Operating instructions AutoFilt English 7.3 Faults and their elimination Any work on the electrical equipment of the back-flushing filter must be carried out by a qualified electrician only! 7.3.1 Troubleshooting – back-flushing filter with electro-pneumatic cyclic control - Fault Fault source Cause Action...
  • Page 166 ® Operating instructions AutoFilt English Fault Fault source Cause Action Continuous back- Differential pressure Setting (optional) of Check the setting of the differential pressure flushing trigger point the differential trigger point, see section 4.4 pressure trigger point If necessary, increase this pressure (optional) is too low Pressure differential Pressure differential...
  • Page 167 ® Operating instructions AutoFilt English 7.4 Removing the filter elements Figure 11: Diagrams for changing the filter elements BA RF4-Standard-deutsch/ englisch/ französisch 01/2007 HYDAC-Document: 03191177f Page 35...
  • Page 168 ® Operating instructions AutoFilt English Item Description Item Description Vent screw Intermediate shaft Quick release clamp Retaining screw for elements Filter bowl Retaining screw for element plate Drain plug Filter elements Top element plate Filter head Table 9: Designation of items of RF4 for changing the elements 7.4.1 Removing the filter elements Before removing the filter elements, check that •...
  • Page 169 ® Operating instructions AutoFilt English 6 bar version: 7. Tighten the bolt on the clamp (Item 2). Screw torque min.5 Nm and max. 27 Nm . Check that the seal between the filter head and bowl does not move. 16 bar version: 7.

  • Page 170: Technical Specifications

    ® Operating instructions AutoFilt English 8 TECHNICAL SPECIFICATIONS Model RF4 - 1 RF4 - 2 Inlet 1“ 1 ½“ Outlet 1“ 1 ½“ Back-flushing line ½“ Coax ¾“ ; Lateal ½“ Maximum operating pressure 6 bar / 16 bar 6 bar / 16 bar Maximum operating temperature 80°...

  • Page 171: Spare Parts

    ® Operating instructions AutoFilt English 9 SPARE PARTS Item Designation Qty. Notes Pneumatic drive XXXXXXXX 1 pc. Position switch XXXXXXXX 1 pc. Differential pressure switch XXXXXXXX 1 pc. Control (SPS) XXXXXXXX 1 pc. Back-flushing valve XXXXXXXX 1 pc. Element kit with seals XXXXXXXX 1 kit Seal kit XXXXXXXX, 1 kit...
  • Page 172 ® Operating instructions AutoFilt English Figure 12: Spare parts RF4-1 BA RF4-Standard-deutsch/ englisch/ französisch 01/2007 HYDAC-Document: 03191177f Page 40...
  • Page 173 ® Operating instructions AutoFilt English Figure 13: Seal kit RF4 Item RF4-1 (6 bar) - RF4-1 (16 bar) - RF4-2 (6 bar) - RF4-2 (16 bar) – coaxial coaxial coaxial coaxial O-Ring 90x2,5 O-Ring 120x2,5 Quad-Ring 14,7x19,94x2,62 O-Ring 21,89x2,62 O-Ring 28x2,5 Pillar ring O-Ring 107,62x2,62 O-Ring 117x4...
  • Page 174 ® Operating instructions AutoFilt English APPENDIX 1) Actuator 1.1) Actuator (EPT) General Inductive proximity switch Pilot valve Vent throttle 1.2) Actuator (ET) 2) Differential pressure switch 3) Control 4) Back-flushing valve Coaxial valve Lateral valve For more detailed information on the components, please contact HYDAC Process Technology GmbH.
  • Page 175 ® Operating instructions AutoFilt English 1) ACTUATOR 1.1) Actuator (EPT) Figure 14: Drawing of actuator The actuator rotates the element plate with the elements over the back-flushing opening if back- flushing is triggered by the differential pressure or the timer. Function principle The element plate is rotated by compressed air.
  • Page 176 ® Operating instructions AutoFilt English Inductive proximity switch In order that the actuator always finds the correct position, a proximity switch is fitted which gives a signal to the control as soon as the "zero position” is reached. Technical specifications Operating voltage: 15 - 34 V DC Current consumption (without load)
  • Page 177 ® Operating instructions AutoFilt English Vent throttle valve Type of mounting: Cartridge thread Port: G 1/4 Nominal width: 5 mm Operating pressure range: 0 to 10 bar The vent throttle is sealed and must not be altered! 1.2) Actuator (ET) Operating voltage / frequency RF4-x-ET1A 240V / 50-60 Hz...
  • Page 178 ® Operating instructions AutoFilt English 2) DIFFERENTIAL PRESSURE SWITCH Figure 16: Differential pressure switch, Type DS 31 The differential pressure switch unit can be used for all neutral media, such as: waste water, heating water, neutral gases, oils etc. It is suitable for two-position controls by means of an infinitely variable switch point between 10 -100% of the pressure range.
  • Page 179 ® Operating instructions AutoFilt English Technical details Pressure ranges 0 - 1 bar Max. stat. operating pressure 16 bar [above or below atmospheric pressure] Permiss. ambient temperature + 80° C Permiss. temperature of fluid + 90° C Pressure chamber brass Membrane Electrical connection Permanently wired number cable...
  • Page 180 ® Operating instructions AutoFilt English 3) PLC CONTROL The power supply and the entire electrical control is located in the control box (Protection class IP 55). All operations are controlled automatically by the PLC. The power supply of the back-flushing filter is switched on and off using the main switch (provided by customer).
  • Page 181 ® Operating instructions AutoFilt English 4) BACK-FLUSHING VALVE The back-flushing valve opens and closes the back-flushing line and therefore either starts or stops the back-flushing of a filter element. There are different types of back-flushing valve Coaxial valve • Lateral valve •...
  • Page 182 ® Operating instructions AutoFilt English TECHNICAL SPECIFICATIONS: Characteristic Coaxial valve Lateral valve Coaxial valve RF4 - 1 RF4 - 1/2 RF4 - 2 Type externally controlled externally controlled externally controlled coaxially laterally coaxially Pressure range PN 0-16 bar PN 0-16 bar PN 0-16 bar Function Normally closed...
  • Page 183 ® Operating instructions AutoFilt English EU DECLARATION OF CONFORMITY HYDAC PROCESS TECHNOLOGY GMBH Industriegebiet Grube König Am Wrangelflöz 1 D-66538 Neunkirchen Telephone (0 68 21) 86 90-0 (0 68 21) 86 90-200 03191177/ 2004 We hereby declare that the product designated below conforms to the basic health and safety requirements of the standards listed below, in respect of its design and construction and in the version in which it is marketed.
  • Page 184 Level sensors LK8124 Electronic level sensor LK Probe length L = 728 mm 3 operating outputs (OUT1...OUT3) 1 overflow output (OUT-OP) Indication of the level as a 8-4-2-1 binary code 7-segment LED display 1: 7-segment LED display 2: Programming button 3: Housing connection with cable lug for cable 1.5 - 2.5 mm²...
  • Page 185 Operating temperature [°C] 0...60 Storage temperature [°C] -25...80 Protection IP 67, III Shock resistance [g] 12 (DIN EN 60068-2-29, 11 ms) Vibration resistance [g] 2.5 (DIN EN 60068-2-6, 10...2000 Hz) EN 61000-4-2 ESD: 4 kV CD / 8 kV AD EN61000-4-3 HF radiated: 10 V/m EN 61000-4-4 Burst:...
  • Page 186 15.+( 3UR[LPLW\ 6ZLWFKHV 3DJH %RWWRP 3ULQWIULHQGO\ YHUVLRQ 4XHVWLRQV" 3UHYLRXV 3DJH 3UR[LPLW\ 6ZLWFKHV 6HH *HQHUDO ,QIRUPDWLRQ IRU 3UR[LPLW\ 6ZLWFKHV ,)0 (/(&7521,& *0%+ E174191 TEICHSTRASSE 4 45127 ESSEN, GERMANY 3KRWR HOHFWULF VZLWFKHV, Fibre-optic type, Cat. Nos. OB, OG, OI, OK, OO or OU, followed by F, followed by blank, followed by C, D, F, H or O, followed by BOW, BOA, NKG or KG, followed by up to 11 letter and/or numbers;...
  • Page 187 letters and/or numbers; Cat. No. KA, KB, KD, KG or KI followed by E or blank, followed by 2 or 3, followed by 008, 010, 015, 020, 050 or 060, followed by A, B or F, followed by BOA, NKG or PKG, followed by up to 15 letters and/or numbers. Cat.
  • Page 188 15.+( 3UR[LPLW\ 6ZLWFKHV &HUWLILHG IRU &DQDGD 3DJH %RWWRP 3ULQWIULHQGO\ YHUVLRQ 4XHVWLRQV" 3UHYLRXV 3DJH 3UR[LPLW\ 6ZLWFKHV &HUWLILHG IRU &DQDGD 6HH *HQHUDO ,QIRUPDWLRQ IRU 3UR[LPLW\ 6ZLWFKHV &HUWLILHG IRU &DQDGD ,)0 (/(&7521,& *0%+ E174191 TEICHSTRASSE 4 45127 ESSEN, GERMANY 3KRWR HOHFWULF VZLWFKHV, Fibre-optic type, Cat. Nos. OB, OG, OI, OK, OO or OU, followed by F, followed by blank, followed by C, D, F, H or O, followed by BOW, BOA, NKG or KG, followed by up to 11 letter and/or numbers;...
  • Page 189 numbers; Cat. No. KA, KB, KD, KG or KI followed by E or blank, followed by 2 or 3, followed by 008, 010, 015, 020, 050 or 060, followed by A, B or F, followed by BOA, NKG or PKG, followed by up to 15 letters and/or numbers. Cat.

  • Page 191: Specifications

    Specifications Model PSD-10 Ceramic sensor Pressure ranges - 1 ... 2.5 -1 ... 4 -1 ... 6 -1 ... 10 -1 ... 16 Over pressure safety Burst pressure Thin-film sensor Pressure ranges Over pressure safety 1200 Burst pressure 1000 1200 1700 2400 Materials...
  • Page 195 Parameter Factory setting Adjustable range Please fill in! Switching output 1 Upper set point Full scale value Pressure range (enter as pressure value) __ __ __ __ Lower set point Full scale value - 10 % Pressure range (enter as pressure value) __ __ __ __ Switching function Switching type...
  • Page 196 Operating instructions Betriebsanleitung Mode d’emploi PSD-10 Electronic pressure switch with display Elektronischer Druckschalter mit Anzeige Pressostat électronique avec visualisation GB F WIKA Alexander Wiegand GmbH & Co. KG Alexander-Wiegand-Straße 30 63911 Klingenberg Germany Tel. (+49) 93 72/132-710 (+49) 93 72/132-706 E-Mail support-tronic@wika.de www.wika.de...
  • Page 201 Specifications Model PSD-10 Ceramic sensor Pressure ranges -1 ... 2.5 -1 ... 4 -1 ... 6 -1 ... 10 -1 ... 16 Over pressure safety Burst pressure Thin-film sensor Pressure ranges Over pressure safety 1200 Burst pressure 1000 1200 1700 2400 Materials Wetted parts...
  • Page 202 Technische Daten Typ PSD-10 Keramiksensor Messbereich -1 ... 2,5 -1 ... 4 -1 ... 6 -1 ... 10 -1 ... 16 Überlastgrenze Berstdruck Dünnfilmsensor Messbereich Überlastgrenze 1200 Berstdruck 1000 1200 1700 2400 Werkstoff Messstoffberührte Teile CrNi-Stahl, bei Keramiksensor zusätzlich Keramik AL , NBR Gehäuse Zink Druckguss Z 410;...
  • Page 203 Caractéristiques techniques Type PSD-10 Capteur céramique Etendues de mesure -1 ... 2,5 -1 ... 4 -1 ... 6 -1 ... 10 -1 ... 16 Limites de surcharge Pression de destruction Capteur à couches minces Etendue de mesure Limite de surcharge 1200 Pression de destruction 1000...
  • Page 205 Functions Display unit Go forward in the menu Setting of a higher parameter value Go back in the menu Setting of a lower parameter value Selection of a parameter value / menu item Acknoweldgement of a parameter value / menu item Calling of the display mode Calling of the programming mode Calling of the reset mode...
  • Page 206 Taste Funktionen Einheit anzeigen Zurückblättern im Menü Einstellen eines größeren Parameterwertes Vorwärtsblättern im Menü Einstellen eines kleineren Parameterwertes Anwählen eines Parameterwertes / Menüpunktes Bestätigen eines Parameterwertes / Menüpunktes Aufrufen des Display-Modus Aufrufen des Programmier-Modus Aufrufen des Reset-Modus Bei gedrückt gehaltener Pfeiltaste ändern sich die Werte der Einstellparameter schneller. Touche Fonctions Affichage des unités...
  • Page 212 Parameter Factory setting Setting range Switch 1 Upper switch point Upper limit of range Measuring range (input as pressure value) rSPI Lower switch point Upper limit of range -10% Measuring range (input as pressure value) Cont Switch type Normally open Normally open noPn Normally closed...
  • Page 213 Parameter Factory setting Setting range Options Password 0000 (= no password) 0000 ... 9999 Unit used Display Actual pressure Max. value Min. value Display off Switch point 2 Switch point 1 Actual pressure Analogue output 4-20 mA 4-20 mA 0-20 mA FroM Initial pressure of the analogue signal Lower limit of range Measuring range =4mA...
  • Page 214 Parameter Werkseinstellung Einstellbereich Schalter 1 Oberer Schaltpunkt Messbereichsende Messbereich (Eingabe als Druckwert) rSPI Unterer Schaltpunkt Messbereichsende -10% Messbereich (Eingabe als Druckwert) Cont Schalterart Schließer Schließer noPn Öffner nCLS Func Schaltfunktion Hysterese Fenster Hysterese dSPI Verzögerung für oberen Schaltpunkt 0,05 s 0,00 ...
  • Page 215 Parameter Werkseinstellung Einstellbereich Optionen Passwort 0000 (= kein Passwort) 0000 ... 9999 Verwendete Einheit Displayanzeige Aktueller Druck Max-Wert Min-Wert Anzeige aus Schaltpunkt 2 Schaltpunkt 1 Aktueller Druck Analogausgang 4-20 mA 4-20 mA 0-20 mA FroM Anfangsdruck des Analogsignals Messbereichsanfang Messbereich =4mA (Eingabe als Druckwert) Enddruck des Analogsignals...
  • Page 216 Paramètres Réglage d’usine Plage de réglage 1er contact point de commutation haut fin de l’EM étendue de mesure (EM) (introduction en valeur pression) rSPI point de commutation bas fin de l’EM -10% étendue de mesure (introduction en valeur pression) Cont genre de contact travail normalement ouvert...
  • Page 217 Paramètres Réglage d’usine Plage de réglage Options mot de passe 0000 (= pas de mot de 0000 ... 9999 passe) unité utilisée affichage pression actuelle valeur maxi valeur mini sans affichage 2ème point de commutation SP2 1er point de commutation pression actuelle sortie analogique 4-20 mA...
  • Page 218 Error Error description Action output Att 1 The parameter value set is lower than the When acknowledging with the OK key, the lower appertaining parameter value parameter value is automatically adjusted. Att 2 The parameter value that is to be set as zero point When acknowledging with the OK key, the is higher than 5% of the span parameter setting is quitted...
  • Page 219 Order-No. / Bestell-Nr. / Numéro de commande 2039080 Fastening clamp / Befestigungsschelle / Bride de fixation 2039098 Programming module incl. software / Programmier-Modul inkl. Software / Module de programmation logiciel inclus...

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