Installation, User and Service Manual Filter Unit WP1-B2-200 Disclaimer: All rights reserved. No part of this publication may be reproduced, stored, or transmitted in any form or by any means, without the prior written permission of GreenOil Standard aps. All information herein is given from our best knowledge and intentions of the time it was released. GreenOil shall not be liable for any damage, losses, costs, or expenses incurred by the purchaser or third parties not covered by the terms agreed by the purchase. Revision: February 2011 File: WB1-B2-200 Manual 30-06-15 1
Installation User and Service Manual Filter Unit WP1-B2-200 Contents Identification 3 Functional description 3 General outline 3 Filter System Functional Principle 4 Installation Wall Mount or Foot Mount 6 Oil Suction Line installation 6 Oil Return Line installation 7 Electrical Connections 8 User Instruction Pressure and Filter monitoring 9 Filter Replacement 9 Pump Pre-filter 10 Filter inserts 11 Service instructions General 12 Motor and pump assembly 12 Pump replacement 13 Pump return screw 13 Pump regulator spring 13 Spare Parts 14 Dimensions 16 2
Identification The filter unit is labelled with a type identification label containing the following information : 1234 Type 10-11B25X1-00 designates a filter unit with suction pump. Serial no.:the type number is followed by an unique series number. Tracking of the unit can be made from the series number. Voltage: Specifies input voltage (230 VAC 50/60HZ) Power: Specifies the maximum total power consumption of the unit in W (VA). Type no.: General Outline Figure 2 shows a WP1-B2-200. From the 1/2 BSP oil inlet (1) oil is sucked through a pump (2). The pump (2) has a built-in pressure control which manage the pressure and flow to accommodate the filter. Pressure is limited to maximum 5 BAR and normal filter pressure is 1.5-3 BAR dependent on filter type, oil viscosity and temperature. The Pump (2) has a build-in suction filter of 200 u. 4 3 2 1 The pump (2) feeds oil to the filter container (4). A water separation chamber is located below the filter. Water is removed from the oil by heated air and leaves the water separator as stem through the outlet (9). 7 6 After filtration and water separation the oil flows to the 1 outlet fitting (5). All electrical connections are made in the motor connection box (6). Power is applied at the cable inlet (7). Total power consumption is approximately 500 W and the power supply is 230 VAC/50Hz. For installation of the unit holes are located in the back side for wall mount. Foot mount can be accomplished by two brackets (8). 9 5 8 Figure 2 Filter pressure is monitored at the pressure gauge (3). 3
Filter System Functional Principle The sectional view next page shows the filter container equipped with all necessary fittings and components. The upper 2/3 of the filter container encloses the replaceable filter canister. The lower 1/3 of the filter container encloses the water separation unit. Oil enters the system under pressure at (1). The built-in pump maintain a steady flow. The filter pressure indicator is also connected here (indicator not shown). In the base oil is directed to the filter centre tube (2) through the evaporation chamber to the filter insert. From the filter centre tube oil enters the filter insert at the top. Basically, the filter consists of two filter materials (3) and (4). The first section of the filter material (3) is chosen with focus on dirt holding capacity and ability to distribute oil throughout the filter. In the second lower part of the filter material (4) is chosen with focus on the ability to filter the desired minimum particles. In general, hydraulic oil require very fine filtration where lubrication oil must be filtered to a degree which does not remove additives. By combining and selecting filter materials, these parameters can be controlled. Oil leaves the filter insert at the bottom (at 5). The filter insert may easily be replaced by loosening a sealed spanner (10). The upper part of the filter container can then be removed and the filter insert replaced. Only oil standing in the centre tube flows from the filter insert and that is taken up by the lower filter container. Thus no oil spill is experienced by filter change, and the used filter insert is only wet where oil leaves the filter. pass from the filter at the rim of the chamber. From the rim of the chamber oil flows as a thin film (6) on the inside of the chamber walls. Oil leaves the evaporation chamber at (7). A heating coil (8) heats the air in the evaporation chamber. The heated air circulates the chamber and exposes the oil film. Due to the very different thermal properties of water and oil, parts of the water content change phase and leave the oil as steam. This creates an overpressure in the chamber, and steam leaves the chamber through the channel (9) to the surroundings. The ability of water to absorb heat is much greater compared to oil. The oil itself is heated 2-3 O C in one pass of the chamber and is not subjected to any heat which may be destructive. The outlet (9) to the atmosphere may be connected to a translucent hose where steam condensation can be seen. Effectiveness of the system is supported by keeping the oil temperature low, which lower the ability of the oil to absorb water. More water is thus emulsified or free, and more willing to leave the oil. The GreenOil system heater consumes 120W to gain a sufficiently high air temperature that makes even absorbed water evaporate. As mentioned, the evaporation chamber is connected to the surrounding atmosphere. To maintain this, the WP1 unit must have a free and unobstructed return line to the system tank or sump. The steam outlet must be left open. As mentioned, oil leaves the filter insert at (5) where it is lead to the rim of the lower filter container by a plate and a mesh (11). The evaporation chamber is sealed from the surroundings in the top by the upper chamber plate (11) which only allows oil to 4
3 10 4 5 11 6 2 8 7 1 9 5
Installation Wall Mount or Foot Mount The filter unit can be mounted on a wall (1) or standing (2) on two brackets delivered with the filter unit. The mounting holes are suited for M8 screws. Allow free space of minimum 180 mm above the filter unit to accommodate filter chance. For additional information dimensions are shown on the drawing page 16. Oil input installation One oil suction line is installed at either (3) or (4). The unused inlet must be plugged. Maximum suction height: 4-6 m Minimum hose diameter for a suction line: 1/2 (for oils above 100 cst the suction line should be increased). Maximum in-let pressure: 0.8 BAR or 10 m oil column (the input pressure is added to the filter pressure). If the oil feed is at pressure it is recommended to install a shut-off valve before the oil in-let. Fitting thread: 1/2 BSP. 3 2 1 4 Oil return line The oil return line (5) is located in the filter unit bottom. Se the page following for installation of the oil return line (5). The steam outlet (6) is also located in the filter unit bottom. A translucent hose may be fitted that will show condensed steam in case the oil contains water. The steam outlet must be left open. 6 5 6
Oil output installation Free Return Line It is very important the oil return hose is let directly to the tank or sump without pockets or obstructions. Furthermore, the filter unit must be installed higher than the maximum oil level in the tank. Due to the small passage in quick coupling, it is not recommended to use these in the return line. The return line entering the tank may either be below or above the oil level in the tank. Fitting thread: 1 BSP. OK NO 7
Electrical Connections MAINS SUPPLY All electrical connections are made in the motor connection box. The following connections are necessary: 1: Inlet Cable relief 2: Power 230VAC N (Neutral) 3: Power 230VAC P (Phase) 4: Power GND (ground) 5: Motor capacitor is connected between (2) and (5). 6: Capacitor 14uF (at 50Hz) and 10uF (at 60 Hz). Note: The unit must be connected to a mains supply with ground (earth). Blk 1 2 Blu 3 5 Br 4 Whi 8
Filter Replacement The filter must only be replaced when the unit is turned OFF and the filter pressure is dropped to 0. If pressure is applied during filter change the sealing rim of the filter container may be damaged. 1. Loosen and remove the spanner (1). 2. Lift off the upper filter container (2). 3. Pull up the used filter insert (3). The filter is sealed by a O-ring (5). Let the oil drain from the filter centre tube. The filter can now be removed without oil spill. 4. Inspect the two O-rings (4) and (5) and replace if necessary. 5. Verify on the filter label that the replacement filter is of correct type for the application. Data on filter inserts is included at the pages following. 6. Insert the new filter canister (3), O-ring (4), upper filter container (2) and spanner (1). If necessary the spanner may be locked by a split. 7. After power is applied filter pressure gets stabilized in approximately 20 minutes. For later use register filter pressure when the filter is stabilized. Pressure and Filter Monitoring Filter pressure depends of oil type, viscosity, temperature and the degree of filter contamination. The pressure gauge can only be used as a reliable indication of filter contamination if a pressure registration was made when the unused filter was installed. Normal filter pressure with a new filter is within the range from 1,2-2,5 BAR dependent of oil viscosity and temperature. Maximum pressure is factory adjusted to 5 BAR. The filter should be changed when pressure rises to 1.5 times the pressure by installation of a new insert provided that temperature is fairly identical. The filter insert must be replaced each year. File: WB1-B1-100 Manual 06-10-12 9
User Instruction: Pump Pre-filter The pump is equipped with a build-in prefilter to protect the pump from damaging particles above 200 u. The filter has a resin mesh. In a normal by-pass application the oil is by definition clean, and the filter does not require service. However, if the system is very contaminated the filter may be blocked. A blocked pre-filter is detected by low filter pressure and lack of ability to suck oil. If the suction line is under pressure the line must be closed in order to prevent excess oil-spill. The filter is removed by loosening the four screws (1) in the pump housing (2). A small amount of oil can be expected to flow out of the pump housing. The filter (4) is carefully cleaned. Reinsert the filter (4) into the pump. The seal (3) is placed over the filter (4). Verify, that the grove (5) fits over the filter. Re-assemble the housing (2) with the screws (1). 10
Data Sheet Filter Inserts Filter Inserts type H Filters type H s applied for deep filtration of hydraulic oils. By filtration down to ISO 12/10/7 or NAS 4 these inserts can be applied in installations requiring the highest demands to oil quality. Hydraulic oil in general sets high demands to oil purity. 80-90 % of all break downs or failures relates to particles contamination. The best solution for preventing unnecessary wear and costly break downs is continuous by-pass filtration. The GreenOil filter technology prolongs component and equipment lifetimes and reduces break downs and maintenance costs by a factor 5 to 10. Technical Data Filter type H Stock Number 2202 H Filter Volume 8 litre Dirt capacity (NIST) 1000g Viscosity @ 40 o C 40-100 cst Cleans to NAS1638 4 Cleans to ISO4406 12/10/7 Expected lifetime 12 month Absolute filter rating* 5 u Filter Inserts type M Filters type M is intended for deep filtration of engine and lubrication oils in engines and transmissions. The filter removes wearing debris and particles from the combustion process, but allows additives to pass. Due to a more or less extensive contamination from the combustion process, lubrication oils in engines are submitted to a much higher degree of contamination compared to hydraulic oils. The GreenOil type M filter is made to have large dirt holding capacity and thus long service life. Even though effective by-pass filtration enhance the oil quality significantly, engine oil must be changed in regular service intervals, due to the wearing up off additives. As a rough rule of thumb the intervals between oil change may be prolonged by a factor 4-8. Alternatively, decisions must be based on regular oil analysis. Technical Data Filter type M Stock Number 2002 M Filter Volume 8 litre Dirt capacity (NIST) 1000g Viscosity @ 40 o C 100-250 cst Cleans to NAS1638 5 Cleans to ISO4406 15/13/10 Expected lifetime 12 month Absolute filter rating* 7 u Filter Inserts type T The filter is designed by the same principle as utilized in the engine oil filter M. However the filter is designed to accept lubrication oils with higher viscosities. Technical Data Filter type T Stock Number 2102 M Filter Volume 8 litre Dirt capacity (NIST) 1000g Viscosity @ 40 o C 200-350 cst Cleans to NAS1638 7 Cleans to ISO4406 17/15/12 Expected lifetime 12 month Absolute filter rating* 9 u * Filter rating specifications acc. to ISO 4406:99 at B(c)=75 11
Service Instruction: Motor and Pump assembly General The only service requiring parts may be motor and pump. The chapters following describes the processes involved where special attention may be required. Motor and pump assembly The pump (1) is disassembled from the motor (2) by in turns loosening the two unbraco screws (5). The pump may then be pulled away from the motor (2). The one piece plastic clutch (6) may be withdrawn from the pump shaft. The pump (1) is assembled into the motor flange (3) by 4 screws (4). When the pump is re-fitted care should be taken to align the clutch (6) with the motor shaft. The two flange screws (5) must be tightened in turns, otherwise the pump will get jammed. 12
Service instructions: Pump Replacement and Modification Pump Replacement As replacement pumps are used in different applications the following must be controlled. Pump Return Screw The pumps has a build in blocking screw which separates the return line from the inlet. This screw must be removed from the pump, because the filter system does not utilize a two string system. 1. Disassemble the sealing plug located as shown. 2. Verify that the pump return screw is not assembled. Assemble the sealing plug again. Pump Regulator Spring Filter pressure ranges between 2-5 BAR witch is regulated by the built in pressure regulator. However, a standard pump is delivered with a regulator ranging from 5-20 BAR, so the pump must be modified unless the pump is labelled 4BAR. 4. Remove the zeeger ring (1). 5. By tightening the regulator screw (2) it is removed from the pump. 6. Replace the spring (3) with the spring from the old pump, alternatively request a new from GreenOil. Neither of the standard springs (4) are used. 7. Assemble the regulator screw (2) and refit the zeeger ring (1). Turn the screw right to the bottom and then turn it back 1.5 turns. 8. By blocking the filter centre tube manually without a filter inserted maximum pressure 5 BAR can be adjusted on the regulator screw (2). 13
Spare Parts: 23 20 31 32 33 30 24 34 22 33 35 36 25 29 26 37 33 35 39 28 38 27 14
Po s Part no. Description 1 50-050-027-0 Filter Housing Top 2 44-6162310 Ø220 Spanner 3 42-OR2150-1000 O-ring Ø215 4 50-020-072-0 Distributing plate 5 50-021-024-1 Top Plate Chamber 6 42-OR01227-262 O-ring Ø12,7 7 50-023-002-0 WP-B1 Centre Tube 8 72-101 120W/230V Heat Coil 9 50-020-032-1 Steam Outlet Tube 10 Included in (8) Sealing Washer 11 50-023-001-0 Stainless Chamber bottom 12 42-OR08532353 O-Ring Ø85,32 13 50-050-026-1 Evaporating Canister 14 40-281-108 M6x12 Cyl. Unbraco 15 32-G-M4-0,8 Nozzle 1 2 3 5 4 6 7 15 22 20-125-151-0 Chassis WP-X1-100 23 30-3609043211 Oil Pump RSH95 24 30-369039030 Low Pressure Spring for Pump 25 30-070-0211 Pump Flange 26 10-9015 Pump Clutch 27 30-9014 Motor 2800/370W 28 50-025-059-0 Floor Mount Bracket 29 40-293-476 Unbraco M10x30 30 60-7012-06-04 Nipple 1/4-3/8 BSP 31 60-7406-02-02 1/8-1/8 Cross Fitting 32 60-7012-02-02 1/8-1/8 Nipple Fitting 33 42-PP45-A 1/8 Seal 34 32-258724 Pressure Gauge 0-6 BAR 35 60-6003-10-03 Ø10x1/8 Tube Union Fitting 36 50-025-058-0 Pressure Tube WP1-X1-100 37 60-7282-02-02 Angle Connection 1/8-1/8 38 51-023-003-0 3/4 G-1 BSP Nipple 39 Motor Capacitor 14uF 13 8 9 11 12 14 10 15
Oil Out 1 BSP Oil In 1/2 BSP WP1-B2-200 Dimensions 16