Bühler technologies BKF User manual

FluidControl
Installation and Operation Instructions
Original instructions
Off-line filter / cooler units
BKF
BE380003
03/2017
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
E-Mail: [email protected]
Internet: www.buehler-technologies.com

Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
Internet: www.buehler-technologies.com
E-Mail: [email protected]
Read this instruction carefully prior to installation and/or use. Pay at-
tention particularly to all advises and safety instructions to prevent in-
juries. Bühler Technologies can not be held responsible for misusing
the product or unreliable function due to unauthorised modifications.
All rights reserved. Bühler Technologies GmbH 2017
Document information
Document No......................................................... BE380003
Version..........................................................................03/2017

BKF
Contents
1 Introduction..................................................................................................................................................................................................................... 2
1.1 Intended use .........................................................................................................................................................................................................2
1.2 Scope of delivery.................................................................................................................................................................................................. 2
2 Safety instructions......................................................................................................................................................................................................... 3
2.1 Important advice................................................................................................................................................................................................. 3
2.2 General hazard warnings ................................................................................................................................................................................. 3
3 Transport and storage .................................................................................................................................................................................................. 5
4 Installation and connection ........................................................................................................................................................................................6
4.1 Requirements to the installation site............................................................................................................................................................6
4.2 Aggregate installation.......................................................................................................................................................................................6
4.2.1 Installing swivel nuts in the fitting body ..................................................................................................................................... 6
4.3 Installing the heat exchanger..........................................................................................................................................................................6
4.4 Hydraulic connection......................................................................................................................................................................................... 7
4.5 Electrical connections ........................................................................................................................................................................................8
4.5.1 Connecting the electric contamination indicator (optional) ................................................................................................. 8
4.6 Bypass, contamination indicator....................................................................................................................................................................8
5 Operation and control ..................................................................................................................................................................................................9
5.1 Before start-up.....................................................................................................................................................................................................9
5.1.1 Flushing the reservoir ........................................................................................................................................................................ 9
5.2 During starting ....................................................................................................................................................................................................9
5.3 Start-up the heat exchanger.......................................................................................................................................................................... 10
5.4 Venting / Ventilation of the heat exchanger............................................................................................................................................10
5.5 Shut-down the heat exchanger ....................................................................................................................................................................10
5.6 Monitoring the filter element .......................................................................................................................................................................10
5.6.1 With visual / electric indicator .......................................................................................................................................................10
5.6.2 No contamination indicator............................................................................................................................................................10
5.7 Impact of Water Quality on Corrosion Resistance ...................................................................................................................................11
6 Maintenance...................................................................................................................................................................................................................13
6.1 Replacing the filter element........................................................................................................................................................................... 14
6.2 Contamination / cleaning the water end .................................................................................................................................................. 14
7 Service and repair..........................................................................................................................................................................................................15
7.1 Troubleshooting .................................................................................................................................................................................................15
8 Disposal........................................................................................................................................................................................................................... 16
9 Appendices......................................................................................................................................................................................................................17
9.1 Technical data .....................................................................................................................................................................................................17
9.1.1 BKF 18 / BKF 30.....................................................................................................................................................................................18
9.1.2 BKF 60 / BKF 90 ...................................................................................................................................................................................19
9.2 Selecting the filter fineness........................................................................................................................................................................... 20
9.3 Cooling capacity curves................................................................................................................................................................................... 21
9.4 Screw torques.....................................................................................................................................................................................................22
9.5 Hose torques.......................................................................................................................................................................................................22
9.6 Calculations ........................................................................................................................................................................................................22
9.6.1 Calculating viscosity ......................................................................................................................................................................... 22
9.6.2 Table of operational viscosity for VG oil ..................................................................................................................................... 22
9.6.3 Calculating the pressure loss ..........................................................................................................................................................23
9.7 Pressure loss in straight pipes.......................................................................................................................................................................23
10 Attached documents................................................................................................................................................................................................... 25
iBühler Technologies GmbHBE380003 ◦ 03/2017

BKF
1 Introduction
1.1 Intended use
BKF Off-line filters are used to filter and cool oil in hydraulic and lubrication circuits. Their scope is given by their specifications.
The use in other applications is not permitted without confirmation by Bühler Technologies GmbH.
1.2 Scope of delivery
– 1 x Off-Line Filter
– Product documentation
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2 Safety instructions
2.1 Important advice
Operation of the device is only valid if:
– the product is used under the conditions described in the installation- and operation instruction, the intended application
according to the type plate and the intended use. In case of unauthorized modifications done by the user Bühler Technolo-
gies GmbH can not be held responsible for any damage,
– when complying with the specifications and markings on the nameplates.
– the performance limits given in the datasheets and in the installation- and operation instruction are obeyed,
– monitoring devices and safety devices are installed properly,
– service and repair is carried out by Bühler Technologies GmbH,
– only original spare parts are used.
This manual is part of the equipment. The manufacturer keeps the right to modify specifications without advanced notice. Keep
this manual for later use.
Signal words for warnings
DANGER
Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.
WARNING
Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not
avoided.
CAUTION
Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or
minor or medium injuries if not avoided.
NOTICE
Signal word for important information to the product.
Warning signs
In this manual, the following warning signs are used:
Warning against hazardous situations Warning against high pressure
Warning against electrical voltage General notice
Warning against hot surface Disconnect from mains
Warning against environmental hazard Wear protection gloves
Warning against potentially explosive atmo-
spheres
2.2 General hazard warnings
The equipment must be installed by a professional familiar with the safety requirements and risks.
Be sure to observe the safety regulations and generally applicable rules of technology relevant for the installation site. Prevent
malfunctions and avoid personal injuries and property damage.
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The operator of the system must ensure:
– Safety notices and operating instructions are available and observed,
– The respective national accident prevention regulations are observed,
– The permissible data and operational conditions are maintained,
– Safety guards are used and mandatory maintenance is performed,
– Legal regulations are observed during disposal.
– Nearby equipment is EMC protected, e.g. through shielding.
– The current and voltage supply for the aggregate has a (mains) separator with adequate switching capacity. National re-
quirements must be observed.
Maintenance, Repair
Please note during maintenance and repairs:
– Repairs to the unit must be performed by Bühler authorised personnel.
– Only perform conversion-, maintenance or installation work described in these operating and installation instructions.
– Always use genuine spare parts.
Always observe the applicable safety and operating regulations in the respective country of use when performing any type of
maintenance.
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
CAUTION Hot surface
Burning hazard
Let the device cool down before maintaining.
CAUTION High pressure
Hazard of injury due to flung off parts or oil, environmental hazard due to oil.
a) Before starting any maintenance or repair to the oil circuit, make sure that the device
is depressurized. This applies to the locking screws as well.
b) Avoid environmental pollution (oil spills) during cleaning or maintenance of the oil
circuit.
c) Use drip pans.
WARNING Voltage flashovers
Electrocution hazard
Do not earth the heat exchanger when carrying out welding work!
DANGER Potentially explosive atmosphere
Explosion hazard if used in hazardous areas.
The device is not suitable for operation in hazardous areas with potentially explosive at-
mospheres.
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3 Transport and storage
The products should be transported only in its original packaging or a suitable replacement. Secure device for transportation.
Only use the engine transport eyes to hoist the engine without add-ons.
Do not use the eye bolts according to DIN 580 in ambient temperatures below -20°C. The eye bolts could fracture in these tem-
peratures, injuring personnel and/or damage the system.
Do not strain the eye bolts more than 45° in the thread direction.
When not in use, protect the equipment against moisture and heat. Keep it in a covered, dry and dust-free room at ambient
temperature.
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4 Installation and connection
4.1 Requirements to the installation site
Aggregate
The aggregate must be set up to allow for unobstructed air flow and adequate room for maintenance/repairs. When installed
outdoors, be sure to consider the motor protection rating (standard: IP 55) and ensure adequate protection from the weather.
When using a filter with visual service indicator, the aggregate must be set up so as not to block the service indicator.
4.2 Aggregate installation
The aggregate mounts to the reservoir cover or a suitable mount with four screws. When installing the aggregate, be sure to
maintain the required removal height for removing the filter element. The contamination indicator must be clearly visible.
To protect the system from damage, the connections must be stress free. We recommend using flexible hoses. Be sure the hose
is stable against negative pressure, e.g. steel wire reinforced. Avoid possible leaks in the circuit to prevent environmental dam-
ages. If necessary, use an oil pan. Protect the aggregate from mechanical impact.
4.2.1 Installing swivel nuts in the fitting body
Proceed as follows:
– Carefully slide the preinstalled pipe end into the 24° cone on the fitting body.
– Tighten the swivel nut until a considerable increase in force can be felt (fixed point).
– Use a suitable spanner to tighten the swivel nut a 1/12 turn more (30°) beyond the fixed point. A marker line on the swivel
nut and the fitting body facilitates observing the correct tightening angle.
Tube
A.D.
Thread Torque (Nm) for straight
screwed plug
Torque (Nm) sealing plug
6 G 1/8" 18 13
8 G 1/4" 35 30
10 G 1/4" 35 30
12 G 3/8" 70 60
15 G 1/2" 90 80
18 G 1/2" 90 80
22 G 3/4" 180 140
28 G 1" 310 200
35 G 1 1/4" 450 400
42 G 1 1/2" 540 450
4.3 Installing the heat exchanger
NOTICE
Piping must always be installed in such a way that no movement in the piping and no
unadmissible forces are transferred to the plate heat exchanger!
CAUTION Damages at the connection
Ensure no vibration is generated in the lines to prevent the plate heat exchanger connec-
tions from being damaged.
Incorrect installation or operation could result in a defect of the welded joint at the con-
nection, hence media mixing.
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WARNING Voltage flashovers
Electrocution hazard
Do not earth the heat exchanger when carrying out welding work!
The designation of the connections on the plate heat exchanger is indicated in the nameplate. Please refer to the decal for the
connection position.
Soldered compact heat exchangers are connected parallel with counter flow. The circuits to be connected must be flushed prior
to making the connection.
The piping to and from the plate heat exchanger must have shut-off valves. In addition, venting must be provided at the highest
position in the upper connections, and drains in the lower connections.
When connection the plate heat exchanger, be sure the seals in the screw connections are clean.
4.4 Hydraulic connection
Water
IN / OUT
Optional:
manometer or
pressure
gauge
Accessories
Output
Inlet
Optional:
manometer or
pressure
gauge
Accessories
Output
Inlet
Wiring diagram BKF 18/30 Wiring diagram BKF 60/90
Carry out the hydraulic connection as shown in the wiring diagram. Connect the lines stress and vibration free, so typically using
hoses.
Be sure to use suitable lines (with regard to pressure, fluid resistance, environmental influences, fire) when connecting to the
hydraulic-, lubrication circuit. Tighten the hose lines with a suitable torque (see appendix).
Contaminated fluids impact the life of the cooling system, we therefore recommend a purity class of 23/19/13 per ISO 4406.
When installing the aggregate onto the reservoir cover, the suction and return pipes immediately go down, vertically, as a
straight pipe. Ensure the thread is sealed well, particularly on the suction end, and use the included seals for the aggregate.
When installing the aggregate next to the reservoir or a different location in the system, the suction- and return bores on the
underside of the aggregate must first be sealed tightly.
With this installation, the suction pipe must not be small than defined by the present threaded connections. If longer suction
pipes are required, the cross-section of the lines may need to be larger so as not to continuously exceed the approved negative
suction pressure of max. 0.4 bar.
For proper evacuation of the suction parts it's advisable to fill the pump or the suction pipe with oil prior to initial start-up and
for long suction pipes. Add some oil to the empty filter housing will usually suffice. Then briefly run the e-motor with the filter
cover open. If the oil level in the filter housing rises, the pump is suctioning properly. Now insert the filter element and close the
filter cover. The unit is now ready for use.
On BKF series aggregates the plate heat exchanger connections are indicated in the nameplate.
The piping to and from the plate heat exchanger must have shut-off valves. When connecting the pipes, be sure the seals for the
screw connection are clean.
Pipes must generally be run so movement in the lines or prohibited forces are not applied to the plate heat exchanger!
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4.5 Electrical connections
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
CAUTION Electrical voltage
Wrong mains voltage may damage the device.
Installation of the device shall be performed by trained staff only. Regard the voltage
given on the type plate. Make sure that the cables have sufficient strain relief.
Fusing
Fusing has to be done due to local standards!
Polarity
Take care of the directional rotation of the motor. The rotation direction is indicated on
the motor housing “M” and an arrow.
The direction of rotation can be changed by reversing any two phases.
Use the applicable local regulations to determine the safety values and the cross-sections of connection leads. The motor and, if
equipped, starting devices must be connected to protective earth.
Lead fuses protect the cables in case of a short circuit, but are not sufficient to protect the motor coils from burning due to over-
load. Therefore, install an adequate motor circuit breaker with high precision range of adjustment for thermal protection to pro-
tect the motor against overload and operation with two phases
Adjust the motor circuit breaker according to the nominal value specified on the type plate of the motor. Operation outside the
specified mains voltage and frequency range limits is prohibited.
Take appropriate measures to protect energised parts from being touched by persons and/or interference from foreign objects.
The operator of the equipment is responsible for ensuring lightning protection.
4.5.1 Connecting the electric contamination indicator (optional)
The electric contamination indicator connects via 2-pin connector plug per DIN43650, with the poles marked 1 and 2.
The top can be attached as an opener or closer by turning by 180°.
4.6 Bypass, contamination indicator
The aggregate features a bypass valve which returns part of the oil flow to the suction line at a pressure drop > approx. 6bar.
We recommend retrofitting the bypass unit with a mechanical/electric display to switch the pump off when the filter element
reaches its contamination capacity and simultaneously output a visual or electric signal.
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5 Operation and control
NOTICE
The device must not be operated beyond its specifications.
5.1 Before start-up
– Check all parts for damage. Do not put a damaged device into operation.
– Verify the connection is correct as described in chapter “Installation and connection”.
– Verify a filter is inside the attached filter housing (the aggregate is delivered without element).
– Check if all valves or other parts which must be open during start-up were opened.
NOTICE
Before starting up a hydraulic system, any contamination from assembly (including in
the oil) must be flushed out.
5.1.1 Flushing the reservoir
On smaller oil reservoirs the oil can also be cleaned via off-line filter during start-up.
This is done with the system off, only the off-line filter is on.
Be sure the coolant supply line is closed to prevent the oil viscosity from dropping and to reduce strain on the filter element due
to cold oil.
During this process the oil should preferably at a minimum be at room temperature. It will heat up further during the cleaning
cycle. So long as the oil temperature does not exceed 60°C, the process may be continued. The coolant supply line may be
opened and the oil temperature lowered via the cooler until the desired oil purity has been reached. Unless otherwise recom-
mended by the system manufacturer, we recommend a minimum purity class of 15/11 per ISO 4406.
Flushing is also required if the oil was added via the off-line filter, since based on the mechanics of the filter only a so-called
single pass is performed.
Flushing is also recommended after changing the oil unless the new oil used meets the specified purity class.
Be sure the filter element does not exceed the filtration capacity, which can occur very quickly (within minutes) during flushing.
Replace the filter element as described in chapter Replacing the filter element [> page14] and continue flushing.
After flushing we recommend documenting the purity class achieved through oil analysis.
After flushing the filter element must always be replaced (see chapter Replacing the filter element [> page14]).
5.2 During starting
First, check that the pump rotates counter clockwise. The direction is marked on the pump housing with M and directional ar-
row.
CAUTION Hot surface
Burning hazard
Let the device cool down before maintaining.
CAUTION High pressure
Hazard of injury due to flung off parts or oil, environmental hazard due to oil.
a) Before starting any maintenance or repair to the oil circuit, make sure that the device
is depressurized. This applies to the locking screws as well.
b) Avoid environmental pollution (oil spills) during cleaning or maintenance of the oil
circuit.
c) Use drip pans.
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Noise level
Our pump is supplied with a low noise. If the noise level increases significantly check if the suction line has the right dimension
and if the pump works in the appropriate temp/viscosity range. Ask Bühler Technologies GmbH for technical advice.
CAUTION Hazard due to high pressure of the pump
Do not exceed the nominal pressure.
Install safety valves (pressure relief valves) to pumps that generate higher pressures.
The pumps feeding the plate heat exchanger must be equipped with control valves. Pumps which generate pressures higher
than those specified for the unit must be equipped with safety valves. The water pump must not suction air to preclude operat-
ing faults through water hammers.
5.3 Start-up the heat exchanger
NOTICE
Pressure surges should be avoided!
To avoid hydraulic shocks the pumps should be started up against minimal opened valves. The valves in the supply and the re-
turn lines should be opened slowly, if possible simultaneously.
5.4 Venting / Ventilation of the heat exchanger
During the filling process the unit must be vented through the vent valves installed in the piping. Plate heat exchangers which
are not vented to a sufficient degree do not achieve full performance because the heating surface is covered by air. Furthermore
the corrosion risk increases when air remains in the unit.
5.5 Shut-down the heat exchanger
The two sides should be shut-down simultaneously and slowly. If this not possible the hot side should be shut down first.
If the cooler is shut down for a long time it should be drained completely and cleaned. The should be specially when there is a
danger of frost and when aggressive media are involved.
5.6 Monitoring the filter element
5.6.1 With visual / electric indicator
If the aggregate is equipped with a visual / electric indicator (option), after cold starting you will be able to tell if contamination
capacity remains or if the element needs to be replaced. Due to the higher oil viscosity and therefore a higher pressure drop dur-
ing warm-up depending on how contaminated the filter element is, the red button on the visual indicator will pop out and an
electric signal triggered.
Push the red button in again once the operating temperature has been reached. If it is immediately tripped again or the electric
signal does not go out after reaching the operating temperature, the filter element will need to be replaced at the end of the
shift.
If the contamination indicator indicates a contaminated element during normal operation, it must be replaced no later than at
the end of the shift (approx. 8 h).
5.6.2 No contamination indicator
The filter element must be replaced after every system test run or flushing cycle. Then follow the instructions of the system
manufacturer.
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5.7 Impact of Water Quality on Corrosion Resistance
The durability chart shown provides a greatly simplified overview of the corrosion resistance of stainless steels and soldering
materials in tap water at room temperature.
Explanations: +
0
-
Good resistance under normal conditions
Corrosion may occur specifically if other factors are rated 0
Not recommended
WATER CONTENT CONCENTRATION
(mg/L or ppm)
TIME LIMIT
Analyse before
AISI 304 AISI 316 254 SMO COPPER NICKEL
Board material Soldering material
Alkalinity (HCO3
-) < 70
70-300
> 300
Within 24 h +
+
+
+
+
+
+
+
+
0
+
0/+
+
+
+
Sulphate[1] (SO4
2-) < 70
70-300
> 300
No limit +
+
+
+
+
+
+
+
+
+
0/-
-
+
+
+
HCO3- / SO4
2- > 1.0
< 1.0
No limit +
+
+
+
+
+
+
0/-
+
+
Electric conductivity < 10 µS/cm
10-500 µS/cm
> 500 µS/cm
No limit +
+
+
+
+
+
+
+
+
0
+
0
+
+
+
pH [2] < 6.0
6.0-7.5
7.5-9.0
> 9.0
Within 24 h 0
+
+
+
0
+
+
+
0
+
+
+
0
0
+
0
+
+
+
+
Ammonium (NH4
+) < 2
2-20
> 20
Within 24 h +
+
+
+
+
+
+
+
+
+
0/-
-
+
+
+
Chlorides (CI-)
also see table below
< 100
100-200
200-300
> 300
No limit +
0
-
-
+
+
+
-
+
+
+
+
+
+
+
0/+
+
+
+
+
Chlorine gas (CI2) < 1
1-5
> 5
Within 5 h +
-
-
+
-
-
+
0
-
+
0
0/-
+
+
+
Hydrogen sulphide (H2S) < 0.05
> 0.05
No limit +
+
+
+
+
0/-
+
+
Free (aggressive)
carbon dioxide (CO2)
< 5
5-20
> 20
No limit +
+
+
+
+
+
+
+
+
+
0
-
+
+
+
Total hardness (°dH) 4.0-8.5 No limit + + + + +
Nitrate[1] (NO3
-) < 100
> 100
No limit +
+
+
+
+
+
+
0
+
+
Iron[3] (Fe) < 0.2
> 0.2
No limit +
+
+
+
+
+
+
0
+
+
Aluminium (Al) < 0.2
> 0.2
No limit +
+
+
+
+
+
+
0
+
+
Manganese[3] (Mn) < 0.1
> 0.1
No limit +
+
+
+
+
+
+
0
+
+
[1] Sulphates and nitrates act as inhibitors for pitting corrosion caused by chloride in pH-neutral environments.
[2] A low pH value (below 6) generally increases the corrosion risk and a high pH value (over 7.5) reduces the corrosion risk.
[3] Fe3+ and Mn4+ are strong oxidisers and can increase the risk of local corrosion in stainless steels.
SiO2 over 150 ppm increase the calcification risk.
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CHLORIDE
CONTENT
MAXIMUM TEMPERATURE
60 °C 80 °C 80 °C 80 °C
= 10 ppm
= 25 ppm
= 50 ppm
= 80 ppm
= 150 ppm
= 300 ppm
> 300 ppm
SS 304
SS 304
SS 304
SS 316
SS 316
SS 316
Ti / 254 SMO
SS 304
SS 304
SS 316
SS 316
SS 316
Ti / 254 SMO
Ti / 254 SMO
SS 304
SS 316
SS 316
SS 316
Ti / 254 SMO
Ti / 254 SMO
Ti / 254 SMO
SS 316
SS 316
Ti / 254 SMO
Ti / 254 SMO
Ti / 254 SMO
Ti / 254 SMO
Ti / 254 SMO
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6 Maintenance
During maintenance, remember:
– The equipment must be maintained by a professional familiar with the safety requirements and risks.
– Only perform maintenance work described in these operating and installation instructions.
– When performing maintenance of any type, observe the respective safety and operation regulations.
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
CAUTION Hot surface
Burning hazard
Let the device cool down before maintaining.
CAUTION High pressure
Hazard of injury due to flung off parts or oil, environmental hazard due to oil.
a) Before starting any maintenance or repair to the oil circuit, make sure that the device
is depressurized. This applies to the locking screws as well.
b) Avoid environmental pollution (oil spills) during cleaning or maintenance of the oil
circuit.
c) Use drip pans.
Under normal operating conditions the aggregates are maintenance free. Preventive maintenance must therefore be routinely
carried out by the operating company.
When doing so, please pay attention to:
– Tight screw fittings,
– Tightness,
– Damage to the aggregate (replace damaged parts),
– Abnormal (unusual) noise and vibration,
– Check warning labels for legibility and damage.
Electrical connections must be checked annually by a licensed electrician.
The outer parts of the motor, especially the cooling fins and the cooling ducts must be kept as clean as possible to ensure suffi-
cient heat dissipation.
Keep in mind the protection class for dust and humidity. Cleaning the device with high pressure cleaners is only allowed if the
motor has the respective protection class.
The motor is equipped with on both sides with sealed ball bearings. The greasing is designed for the total lifetime. Maintenance
(subsequent greasing) is not necessary.
The motor bearings must be replaced by personnel authorized by Bühler only.
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Condensate drain holes at motors from manufacturer WEG
If the motor is used in surrounding with high humidity this could lead, depending on the ambient temperature, to formation of
condensate inside the motor housing. Specially at longer nonoperation period. The motors of WEG have a condensate drain plug
which can be used for draining off. Pull out the plug according to the pictures and push it then back. If the plug is not pushed
back or completely removed, the motor losses the IP degree of protection.
Condensate drain bore
(plug)
closed position open position plug
6.1 Replacing the filter element
– Shut off aggregate and relief the filter on the pressure end.
– Unscrew the filter cover counter-clockwise.
– Remove the filter element to the top by slightly moving it back and forth.
– Check the O-ring inside the filter cover for damage. Replace if necessary. Be sure the spring washer (possibly still attached to
the filter element) inside the filter bowl is located above the filter seat at the bottom of the filter bowl.
– Verify the replacement element matches the old element.
– Slide the element over the holder inside the filter bowl.
– Now screw the cover hand tight onto the filter bowl.
– Switch the aggregate on again.
6.2 Contamination / cleaning the water end
When using coolants which may be contaminated, e.g. surface water, cooling system water (open circuit) or similar, use filters
with a mesh size of max. 0.6mm. Furthermore, use the highest possible mass flow for these mediums. If the mass flow (partial
load) is too low, the turbulence in the plate heat exchange may drop and the tendency toward contamination increase.
Clean regularly if deposit can be expected due to the water quality (e.g. hard water or high contamination level). Flushing is a
cleaning option. A weak acid, e.g. 5% phosphoric acid, should be used for cleaning. If possible, flush in the direction opposite the
direction of operating flow, if necessary install back-flushing connections in the pipe. Then adequately flush with clean water to
remove any detergent residue before putting the system back into service.
When taking the aggregate out of service for extended periods, particularly aggregates operated with water prone to biological
fouling, we recommend completely draining and cleaning the system to prevent the aggregate from clogging or corroding. This
also applies to danger of frost and aggressive waters.
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7 Service and repair
This chapter contains information on troubleshooting and correction should an error occur during operation.
Repairs to the unit must be performed by Bühler authorised personnel.
Please contact our Service Department with any questions:
Tel.: [phone] or your agent
If the equipment is not functioning properly after correcting any malfunctions and switching on the power, it must be inspected
by the manufacturer. Please send the equipment inside suitable packaging to:
Bühler Technologies GmbH
- Reparatur/Service -
Harkortstraße 29
40880 Ratingen
Germany
Please also attached the completed and signed RMA decontamination statement to the packaging. We will otherwise be unable
to process your repair order.
You will find the form in the appendix of these instructions, or simply request it by e-mail:
[email protected].
7.1 Troubleshooting
Problem / malfunction Possible cause Action
Insufficient pump capacity – Motor direction of rotation incorrect – Correct connection, see chapter Electrical
connections
– Motor doesn’t start – Correct connection, chapter Electrical con-
nections
– Oil flow too low – Increase oil flow
– Oil circuit blocked – Open valves and cocks
Loud pump – Negative intake pressure too high – Select a large enough suction hose
– Reduce suction lift
Cooling capacity too low – Coolant supply line closed – Open the water supply line
– Coolant contaminated – Cleaning the cooler
Tab.1: Troubleshooting
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8 Disposal
Dispose of the parts in such a way that does not present a danger to other people’s heath or to the environment. Observe the
legal requirements in the country of use for the disposal of electrical components and oils and coolants.
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9 Appendices
9.1 Technical data
Technical data
Pump housing: Anodised and impregnated cast aluminium
Gerotor: Sintered steel
Hydraulic screw joint: Galvanised steel
Operating fluids: Mineral oils per DIN 51524
Operating oil temperature: max. 80 °C (higher temperatures on request)
Seal: Perbunan (NBR)
or Viton (FPM) on request
Ambient temperature: -20 °C to +40 °C
Electric motors
Voltage / frequency
BKF 18:
BKF 30:
BKF 60/90:
230/400 V - 50 Hz ± 5 %
276/480 V - 60 Hz ± 5 %
220/380 V - 230/400 V - 240/415 V 50 Hz
460 V 60 Hz
220/380 - 245/420 V 50 Hz
220/380 - 280/480 V 60 Hz
Thermal stability: Class of insulation F,
utilisation per Class B
Design: three-phase asynchronous squirrel-cage induction motor
totally enclosed, fan cooled
Protection class: IP55
on request: other voltages
higher motor power for higher viscosities
UL- or CSA-approved motors
higher protection class
The motors comply with standards
IEC 60034, IEC 60072, IEC 60085
Please also observe the operating manual for the motor! All motors are supplied with cable gland inside the terminal box. The
total height of the aggregate may vary by motor make.
Installation information:
The connection threads are manufactured to ISO 228. The screw-in surfaces are finished and suitable for the use of soft seals. We
recommend using screwed plugs per ISO 1179-2.
Please note:
Especially note the dimension of the suction pipe. The cross-sections should not be smaller than specified. In most cases, loud
noise indicates the cross-section was reduced too much.
Please refer to the notices in the operating instructions.
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9.1.1 BKF 18 / BKF 30
Heat exchanger
mount
Contamination indicator
(optional)
Screw-in connection
Plate heat exchanger
Aggregate mounting diagram
View A
Oil OUT
Water IN
Water OUT
Note: When installing next to the oil reservoir please not the intake!
When determining the bores on the reservoir be sure the contamination indicators remains visible!
Model: BKF 18-6-0.55* BKF 30-4-0.75-IE3**
Motor power: 0.55 kW 0.75 kW
Number of poles: 6 4
Power input (400 V 50 Hz): ~ 1.7 A ~ 1.6 A
Suction lift: 2 m 2 m
Filter element pressure limit: 6 bar 6 bar
Display pressure contamination indicator: 2.2 bar 2.2 bar
Suction end connection: G3/4 / G1 G3/4 / G1
Suction end hose: DN 20 / DN 25 DN 20 / DN 25
Pressure end connection: G3/4 G3/4
Pressure end hose: DN 20 DN 20
Suction pressure:
For all aggregates briefly:
-0.4 bar -0.4 bar
-0.6 bar
Connection "Water IN": G1/2 G1/2
Connection "Water OUT": G1/2 G1/2
Flow rate: 18 L/min 28 L/min
Max. feed pressure: 6 bar 6 bar
Weight: approx. 20 kg approx. 23 kg
*Upon request: Electr. motor per NEMA, UL, CSA, EAC approval
**Electr. motor per NEMA, UL, CSA, EAC approval
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