RBF-E FILTER - Mayfran

Technische DokumentationREV. 3/ 04-18
MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 [email protected] P24-01-07 M_RBF 100- 1500_v02_en
RBF-E FILTER
REV. 3/ 04-18
CONTENTS
1 GENERAL ....................................................................................................................................... 3
1.1 MANUAL ..................................................................................................................................... 3 1.2 ILLUSTRATIONS ........................................................................................................................... 3 1.3 SYMBOLS USED ........................................................................................................................... 3 1.4 COPYRIGHT ................................................................................................................................ 3
2 READ PRIOR TO OPERATION ...................................................................................................... 4
2.1 THE INITIAL FILLING OF THE FILTER SYSTEM: ................................................................................. 4 2.2 BACKGROUND: ............................................................................................................................ 4 2.3 AVOID SOAPING: ......................................................................................................................... 4
3 FILTER RBFE .................................................................................................................................. 6
3.1 BASIC OPERATION ....................................................................................................................... 6 3.2 OPTION TANK FLUSHING .............................................................................................................. 7 3.3 TROUBLESHOOTING .................................................................................................................... 9
4 MAINTENANCE ............................................................................................................................ 10
4.1 WEEKLY CHECKS ...................................................................................................................... 10 4.2 OTHER CHECKS ........................................................................................................................ 11 4.3 EVERY 3 MONTHS ..................................................................................................................... 11
5 SPARE PARTS ............................................................................................................................. 12
RBF-E FILTER MANUAL PAGE 3
REV. 3/ 04-18
1 GENERAL
1.1 MANUAL
1.2 ILLUSTRATIONS
The illustrations in this manual may be based on one type of machine only and may differ from your version. All instructions are applicable to all machines covered by this manual.
1.3 SYMBOLS USED
DANGER
This is a hazardous situation which, if not avoided, will result in death or serious injuries.
WARNING
This is a hazardous situation which, if not avoided, could result in death or serious injuries.
CAUTION
This is a hazardous situation which, if not avoided, could result in minor or moderate injuries.
NOTICE
This is a situation which, if not avoided, could result in material and/or environmental damage.
1.4 COPYRIGHT
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise without written permission of the publisher, Mayfran International BV Landgraaf. This publication is designed to provide accurate and authoritative information in regard to the subject matter covered. The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this manual and cannot accept any responsibility or liability for any errors or omissions that it may contain.
REV. 3/ 04-18
2 READ PRIOR TO OPERATION
The operator of the system should inform the coolant supplier before initial filling.
2.1 THE INITIAL FILLING OF THE FILTER SYSTEM:
Before the initial filling with cooling lubricant, fill the complete system with a detergent and let it circulate for several hours.
When using oil, it should first be tested on filterability.
When using emulsion; o Concentrate can be used with emulgators that suppress an occurrence of foaming. o Demineralized water can be used or water with a hardness of max. 150 ppm Ca-
carbonate. o A dosing and mixing system can be used. o The newly filled system needs to circulate the emulsion over the complete system for
2-4 hours before the machine starts to process.
2.2 BACKGROUND:
Foreign liquids that have remained in the system during the trial run by the machine manufacturer and/or dirt deposits that have gotten into the system during installation work, should be removed from the system before the system is treated with the cooling lubricant. The cooling lubricant supplier should advise. When using oils, the filter performance can be greatly reduced depending on:
viscosity of the oil
additives
surface tension If the data from the oil supplier is insufficient and the influence can lead to a reduction or problems with filterability, the oil should be checked in our laboratory. 1 liter of clean oil is enough for a laboratory check. When using emulsions or dissolutions, soaps should be avoided under all circumstances. Soaps are calcium compounds that are formed either by anti-foam additives or by the water quality. Soap formation leads to sludging of the filter surface, which leads to:
Constant feed of the filter
High residual contamination in the clean tank
High residual moisture in the dirt collector
Sludging of pipes and valves
2.3 AVOID SOAPING:
Water (90-95% of the emulsion) should be chemically neutral and stable. Contact the local authority for the detail of quality of the urban water. If the urban water contains <150 PPM calcium carbonate, it can be used. However, if a higher concentrate is given, the initial filling should take place with demineralized water which can be generated either externally or along an internal desalination plant. Concentrate (5-10% of the emulsion) should allow the soft water approach described above. Concentrates of the new generation contain emulsifiers which by virtue of their chemical composition suppress foaming and make additives unnecessary.
REV. 3/ 04-18
The mixture of water concentrate, the emulsion, should be prepared by means of a suitable dosing and mixing device to ensure homogeneity and quality. A fresh emulsion contains a relatively high proportion of air. Deairing of the emulsion should take place to avoid foaming. Circulating the emulsion for about 2-4 hours under low pressure (10-30% of the plant's capacity) wil result in deairing. At the beginning, a foam collar can form on the coolant surface. However, this dissolves independently during the circulation. Antifoam products are not needed and should be avoided as anti-foam production leads to calcium soaps. These soaps need to be avoided as well. Comment: Although the coolant supplier should give advice, the practice shows that coolant suppliers are not always familiar with new generation filtration systems. We as a filter manufacturer do not want the operator of the system to encounter system problems caused by coolant problems. Those problems only can be solved by a coolant change and leads unnecessarily money and time loss.
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3 FILTER RBF-E
3.1 BASIC OPERATION
Dirt coolant enters the filter housing via the filter inlet. While the coolant can pass the fine mesh covered filter drum, dirt is caught and form a dirt layer, the filter cake, which improves the degree of filtration. At the same time this filter cake reduces the flow through the filter medium and causes a raising of the coolant level in the filter housing. Due to this raising coolant level, a differential height is created between inside and outside of the filter drum, the hydrostatic pressure. The hydrostatic pressure improves the lifetime of the filter cake. Finally the coolant level raises so far the level switch will be activated. In order to continue the filter belt has be cleaned, the filter indexing.
During indexing, the filter belt will be cleaned until the coolant level falls below the level switch by rotating the filter drum and at the same time. Mechanically the belt is cleaned by rotating the brush in order to discharge the dirt layer into a sludge bin. Hydraulically the belt is cleaned by back flushing the filter drum from the inside with cleaned coolant in order to clean the meshes of the filter belt. As soon as the level switch is free, both drives as well as back flushing will stop.
REV. 3/ 04-18
3.2 OPTION TANK FLUSHING
A filtration is never 100%. Fines that passed the filter screen end up in the clean tank and settle down to the tank bottom. Tank flushing will minimize (not eliminate) this settlement. A certain pollution will always remain in the clean coolant tank. The clean coolant tank has only to be cleaned when:
the pump will be endangered by dirt.
the coolant need to be replaced Mostly, the filter back flush pump is used for both, filter back washing AND tank flushing. Therefore, the pipe work is equipped with a 3-way valve activated by a solenoid valve. The filter back washing has highest priority. When level high in filter switch is activated 3-way valve switches to back wash mode. When the filter is not back washed, 3 way valve will be in tank flush mode.
In tank flush mode, special nozzles are used which are capable to increase circulating capacity by ejecting coolant into the clean tank. The increased circulating flow creates a turbulence in the clean tank and reduces settlements of fines to a minimum.
REV. 3/ 04-18
As a liquiphant is installed as level switch, in bypass a small flow is used for cleaning the level switch
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3.3 TROUBLESHOOTING
Due to incorrect belt cleaning or a lack of maintenance, the belt is probably partly plugged. Remove the topcover and clean the belt by using a high pressure cleaner. Clean the belt from the outside to the inside. Check the nozzles and replace if necessary.
Caution Filter indexes too much
Filter indexes too long
Too high flow to filter
Incorrect cleaning of filter belt. Possibly a part of the filter medium is plugged
Coolant problem
Machine supply pumps Check pressures. Note: Lower pressures means higher flow.
• Additives used? • Different coolant? • Is the quality of the coolant ok? • Tramp oils in coolant? Advise from coolant supplier required. Do not try to solve a chemical problem yourself
Incorrect mechanical cleaning o Brush worn out
o Adjust the brush
o Flush pump damaged
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4 MAINTENANCE
Nozzle check
It is extremely important to check the back flush nozzles every week:
Open the inspection opening
Activate level switch manually *)
Check whether all the nozzles are spraying.
*) Manually activating the level switch The level switch is designed as a floater switch or a liquiphant:
The floater switch can be activated by operating the limit switch at the drive side of the filter.
When a liquiphant is used you can either o take off junction-box at switch, keep a magnet onto the housing of the
switch (for details separate manual of the liquiphant). o Alternative it is possible to regenerate a signal from control panel (not
standard).
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4.2 OTHER CHECKS
Check filter screen on damages by operating the filter drum manually. Check filter back washing pressure – Pressure > 3 Bar / Nozzles. Check drum seal. The presence of Item 2 guaranties the sealing. Check electrical components.
4.3 EVERY 3 MONTHS
Clean the filter screen by using high pressure cleaning unit. Open the inspection cover, use high pressure unit to clean filter screen from the outside to the inside. Cleaning the filter screen extends the lifetime. For necessary maintenance of the components, see the separate component manuals
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5 SPARE PARTS
When ordering parts always mention the serial number of the machine. RBFE-110 Filter drum RBFE-120 Frame model 1, refers to float type of level switch and centre rollers RBFE-121 Frame model 2, refers to liquiphant type of level switch and centre rollers RBFE-130 Brush RBFE-140 Hydraulic filter belt cleaning RBFE-150 Drum seal RBFE-160 Drum drive assembly
REV. 3/ 04-18
5.1 FILTER DRUM
1 1 Filter screen 80.55.XX* #
2 Belt seal Drawing RBFE-150 #
3 1 Drum wall drive 90.03.01
4 1 Drum wall outlet 90.03.00
5 1 Drive sprocket 90.10.01
6 3 Scraper 90.91.YY*) #
RBF-E600 – E1000
1 1 Filter screen 80.55.XX* #
2 Belt seal Drawing RBFE-150 #
3 1 Drum wall drive 90.03.11
4 1 Drum wall outlet 90.03.10
5 1 Drive sprocket 90.10.02
6 5 Scraper 90.91.YY*) #
7 1 Protection plate 90.01.28 #
*) RBF-E100 RBF-E200 RBF-E300 RBF-E400 RBF-E600 RBF-E1000 XX 01 02 03 04 06 10 YY 01 02 03 04 04 06
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5.2 FRAME: MODEL 1
(refers to float type of level switch and centre rollers)
RBF-E100 – E200 – E300 – E400
1 1 Frame
3 3 Centre roller Plastic 90.07.02 #
4 1 Hydraulic belt cleaning
Drawing RBF-E140
7 1 Drive unit Drawing RBF-E160
8 1 Floater 90.06.10 #
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5.3 FRAME MODEL 2
(refers to liquiphant type of level switch and center rollers)
RBF-E100 – E200 – E300 – E400
1 1 Frame
3 3 Center roller Steel 90.07.05 #
Drawing RBF-E140
7 1 Drive Drawing RBF-E160
RBF-E600 – E1000
1 1 Frame
3 5 Center roller Steel 90.07.05 #
RBF-E140
7 1 Drive Drawing RBF-E160
REV. 3/ 04-18
5.4 BRUSH
1 1 Drive unit Varvel MRT 40 - 0,55 kW #
2 1 Torque arm Varvel BTV 40
3 1 Frame 91.30.RBFE
4 1 Brush 90.05.RBFE #
8 1 Insert 90.15.RBFE
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5.5 HYDRAULIC FILTER BELT CLEANING
Pos Part Qty Description Manuf. Type Part S
1 X Nozzle 90B2CM06E65 90.90.02 #
2 1 Nozzle ramp type 1 90.91.RBFE
3 1 Nozzle ramp type 2 90.92.RBFE
Number of nozzles RBF-E100 RBF-E200 RBF-E300 RBF-E400 RBF-E600 RBF-E1000
X 5 11 16 21 21 32
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5.6 DRUM SEAL
1 1 Drum seal 90.06.021 #
2 1 Secundary seal O-Ring 596 x 5 #
3 2 Tension belt 54700010
4 2 Belt seal CM 212 B #
5 1 Filter drum Drawing RBFE-110
6 1 Filter frame Drawing RBFE-120
RBF-E600 – E1000
1 1 Drum seal 90.06.022 #
2 1 Secundary seal O-Ring 940 x 5 #
3 2 Tension belt 54700010
4 2 Belt seal CM 212 B #
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5.7 DRUM DRIVE ASSEMBLY
RBF-E100 – E200 – E300 – E400
1 1 Gear unit Varvel MTA 80/70 – 0,37 kW #
3 Shims 90.95.01
5 1 Bearing INA PCJT-30 40.01.30
7 1 Brush Drawing RBFE-130
9 1 Oil seal CB60-40-12
RBF-E600 – E1000
1 1 Gear unit Varvel MTA 80/85 – 0,55 kW #
3 Shims 90.95.02
5 1 Bearing INA PCJT-40 40.01.40
7 1 Brush Drawing RBFE-130
9 1 Oil seal CB60-50-12

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RBF-E FILTER - Mayfran