Filtration Group Pi 21430 User manual

Translation of the original instructions with installation instructions
Duplex filter
Pi 214
Mat. No. of original instructions
72464269

Page 2
Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
1 Contents
1Contents...................................................................... 2
2General safety instructions....................................... 2
2.1 Safety instructions for installation and
operating personnel .......................................... 2
2.2 Warning structure.............................................. 2
2.3 Warning symbols used...................................... 2
2.4 Other symbols used.......................................... 3
3Glossary...................................................................... 3
4General information ................................................... 3
4.1 Manufacturer..................................................... 3
4.2 Information about the original instructions ........ 3
4.3 Negative declaration ......................................... 3
5Intended use............................................................... 4
6Functional description............................................... 4
6.1 Principle of the process..................................... 4
6.2 Main components of the duplex filter ................ 5
6.3 Operating principle of the duplex filter............... 5
7Technical data ............................................................ 6
7.1 Order-specific data............................................ 6
7.2 Technical data of the duplex filter ..................... 6
7.3 Technical data of the standard maintenance
indicator (PiS 3097) .......................................... 6
8Transport and storage ............................................... 6
9Installation .................................................................. 6
9.1 Installation......................................................... 6
9.2 Pressure relief................................................... 6
10 Start-up ....................................................................... 7
11 Normal operation ....................................................... 7
11.1 Filters without a maintenance indicator............. 7
11.2 Filters with a maintenance indicator
(optional)........................................................... 7
11.3 Filtration of cooling lubricants ........................... 7
12 Troubleshooting......................................................... 7
13 Maintenance ............................................................... 7
13.1 Maintenance work on the parallel unit............... 7
13.2 Maintenance work on the duplex filter............... 8
13.3 Inspection and maintenance schedule.............. 9
13.4 Replacing the filter element .............................. 9
13.5 Cleaning the filter housing .............................. 10
13.6 Cleaning the wire cloth elements.................... 10
14 Assembly drawing ................................................... 11
15 Options table ............................................................ 13
16 Spare parts drawing................................................. 15
17 Recommended spare parts and accessories ........ 16
18 Negative declaration ................................................ 17
19 Index.......................................................................... 18
2 General safety instructions
2.1 Safety instructions for installation and
operating personnel
This translation of the original instructions contains
important safety information which must be heeded at all
times during installation, normal operation and
maintenance.
Non-observance can result in the following risks to persons
and the environment as well as in damage to the machine
or system:
Failure of critical functions of the machine or system or
of its component parts.
Danger to persons from electrical or mechanical effects
as well as from chemical reactions.
Danger to the environment owing to the leakage of
hazardous substances.
Before installation / start-up:
•Read this translation of the original instructions carefully.
•Make sure that installation and operating personnel are
adequately trained.
•Make sure the contents of the original instructions are
fully understood by the responsible persons.
•Define areas of responsibility and competence.
•Prepare a maintenance schedule.
During operation of the system:
•Keep this translation of the original instructions handy at
the place of use.
•Heed the safety instructions. Always operate the
machine or system in accordance with its ratings.
If in doubt:
•Consult the manufacturer.
2.2 Warning structure
Where possible, warnings are structured according to the
following system:
Signal word
Possibly
with
symbol
Nature and source of the danger
Potential consequences of non-
observance
•Action to avert the danger.
2.3 Warning symbols used
DANGER!
Immediate danger!
Non-observance will result in serious or fatal injury.
WARNING!
Potentially dangerous situation!
Non-observance can result in serious or fatal injury.
CAUTION!
Potentially dangerous situation!
Non-observance can result in minor or moderate
injuries.
IMPORTANT!
Potentially dangerous situation!
Non-observance can result in property damage.

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Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
2.4 Other symbols used
Danger: High voltage!
Danger information about explosion
protection
Information about environmental protection
Wear protective clothing!
Eye protection must be worn!
Respirator must be worn!
Hand symbol:
Indicates general information and
recommendations
•
Bullet:
Indicates the order in which
actions are to be carried out

Arrow:
Indicates responses to actions
3 Glossary
Initial differential pressure
Differential pressure at the start of the filtration process
(when the filter element is “clean”).
Differential pressure (∆p)
Pressure difference between the dirty side and the clean
side.
Filter element
Cylindrical support structure with star-pleated filter material.
The substance to be filtered flows from the outside to the
inside. Solids are retained on the outer surface of the filter
element.
Filtrate
Substance to be filtered.
Cooling lubricant
Cooling lubricant according to DIN 51385.
4 General information
4.1 Manufacturer
Filtration Group GmbH
Schleifbachweg 45
D-74613 Öhringen
Phone [phone]
Fax [phone]
[e-mail]
www.industrial.filtrationgroup.com
4.2 Information about the original instructions
FG Mat. No..........................................................72464269
Date: .....................................................................16.01.19
Version: ..........................................................................00
4.3 Negative declaration
Our fluid filtration and automatic filter products are
designed for Group 2 fluids (not dangerous) as standard as
defined by the EC Pressure Equipment Directive
2014/68/EU Article 13 and Article 4 (3), in other words a
name-plate without a CE marking is affixed to these
products. No declaration of conformity may be issued for
this reason.
According to the criteria laid down in Article 2 of the
Machinery Directive 2006/42/EC, our standard hydraulic
filters are outside the scope of this directive. Under legal
provisions, therefore, we are not allowed to affix a CE
marking, nor are we permitted to issue a declaration of
incorporation or conformity.

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Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
5 Intended use
DANGER!
Operation contrary to the intended purpose can be
dangerous!
The manufacturer is discharged from all liability and all
warranty claims are rendered invalid.
This duplex filter is only allowed to be used in
accordance with the operating conditions specified in
the contract documentation and in the original
instructions.
All forms of use which deviate from or exceed the
limits of use described above are considered to be
contrary to the intended purpose.
DANGER!
Operation contrary to the intended
purpose can be dangerous!
The manufacturer is discharged from all
liability and all warranty claims are
rendered invalid.
Prohibited:
Use for other purposes without prior
consultation with the manufacturer.
Use in hazardous areas unless explicitly
mentioned in the contract
documentation.
Use with smouldering, burning or sticky
particles.
Use with highly explosive fluids or
pastes.
The standard version is designed for Group 2 fluids as
defined by the EC Pressure Equipment Directive
2014/68/EU Article 4 (3) and Article 13.
6 Functional description
6.1 Principle of the process
Duplex filter
The parallel unit allows you to use each filter individually.
Any maintenance work can thus be carried out without
interrupting the filtration process.
Filtration
A star-pleated filter element is mounted on a cylindrical
support structure; the filter rating is determined by the
element type. The medium flows through the filter element
from the outside to the inside. Solid particles are retained.
The star pleat results in a larger effective filter surface.
Fig. 1: Separation principle at the filter element
Support structure
Filter material

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Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
6.2 Main components of the duplex filter
Fig. 2: Diagram of the main components
1
Maintenance indicator (optional)
2
Vent screw (filter 1)
3
Inlet
4
Filter head
5
Switch-over handle with integrated pressure
compensation lever and safety catch
6
Filter housing (filter 1)
7
Drain plug on dirty side (filter 1)
(standard with NG 300)
8
Drain plug on dirty side (filter 2)
(standard with NG 300)
9
Filter housing (filter 2)
10
Outlet
11
Vent screw (filter 2)
12
Filter element (filter 1)
13
Filter element (filter 2)
6.3 Operating principle of the duplex filter
Fig. 3: Operating principle
1
Dirty fluid flows in through the inlet.
2
The fluid is fed to the left or right filter side, depending on
the position of the switch-over handle. The handle position
indicates the non-operational filter side.
3
The fluid flows through the filter element to the clean side.
4
The filtered fluid exits the duplex filter via the outlet.
5
When a maximum differential pressure is reached, the
switch-over handle must be shifted to the other side and
the dirty filter element replaced with a new FG element.
Wire cloth elements can be cleaned (refer to section 13.6).
Disposable filter elements (PS / MIC / SMX) must be
exchanged and disposed of correctly.
The filtration process is not interrupted.
Optional
If a maintenance indicator is used, a signal is output when
the maximum differential pressure is reached.
1
4
5
2
6
78
9
10
3
11
12 13
12
3
4

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Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
7 Technical data
7.1 Order-specific data
The order-specific data can be taken from the name-plate.
7.2 Technical data of the duplex filter
Nominal pressure
Pi 21430:
2ˣ106load changes:.............................................. 100 bar
Test pressure
Pi 21430:............................................................... 143 bar
Temperature range:................................ -10°C to +120°C
Bypass setting*:..................................... Δp 3.5 bar ± 10%
Maintenance indicator setting*:.............. Δp 2.2 bar ± 10%
Filter housing material: .................................................. St
Filter head material:.................................................. GGG
Sealing material:.............................. NBR / PTFE / Cu / Al
Maintenance indicator material: .................................... Al
7.3 Technical data of the standard maintenance
indicator (PiS 3097)
Switch: ..................................... NC / NO with reed contact
Protection class: ........................................................ IP65
NO / NC contact load:.......................................Max. 70 W
.................................................. Max. 250 VAC / 200 VDC
............................................................................ Max. 1 A
As-delivered condition: ............................ Normally closed
8 Transport and storage
Transport
•Always transport in the original packaging.
•Avoid vibration.
Storage
•Always store in the original packaging.
•Always store in a dry, frost-free room.
*Other pressures possible if conditions deviate from standard.
9 Installation
DANGER!
Danger if unauthorised work is carried out
on the unit!
Risk of injury to persons or damage to
property.
The unit is only allowed to be installed,
accepted and tested by a qualified person
(99/98/EC).
WARNING!
Danger if unauthorised work is carried out on the
unit!
Risk of injury to persons or damage to property.
All installation work must be carried out by a suitably
trained person.
9.1 Installation
It must be possible to remove the filter
element in order to carry out maintenance
work.
Use only suitable, chemically resistant seals
for the piping.
Prepare a suitable location for installing the unit.
Make sure sufficient free space is available for removal
and draining (refer to section 14).
Unpack the duplex filter.
Install the duplex filter with the housings pointing
downwards. Fastening threads are provided on the top
(for dimensions, refer to section 14).
Remove the protection caps from the connections.
Connect the pipes to the duplex filter without stress
(refer to the arrow on the filter head).
Fig. 4: Mechanical installation
9.2 Pressure relief
Design measures must be incorporated to prevent
inadmissible excess pressure on the dirty side.
Install pressure relief devices if necessary.
For space for
removal,
f
Drain
dirty side
Drain
dirty side

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Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
10 Start-up
DANGER!
This duplex filter must not be put into service until the
relevant machinery into which it is to be incorporated has
been declared in conformity with the applicable EC
directives, harmonised standards, European standards or
equivalent national standards.
Loosen the vent screws of the two filters at least one
turn.
Operate the switch-over handle.
The safety catch is released.
The pressure compensation lever opens.
Shift the switch-over handle to the middle position.
Fluid flows through both filters.
Close the vent screws as soon as fluid exits from them
(torque: 25 Nm).
Recover any leaking fluids in a suitable vessel.
Shift the switch-over handle to the required position so
that it contacts the stop.
Check that all pipe connections are tight.
The duplex filter is ready for operation.
11 Normal operation
Please always ensure that you have a
sufficient quantity of original FG replacement
elements in stock. Disposable filter elements
(PS / MIC / SMX) cannot be cleaned.
The following parameters must be monitored daily
during normal operation:
Differential pressure (if the optional maintenance
indicator is installed)
11.1 Filters without a maintenance indicator
Replace the filter element after the trial run or after
flushing the unit.
Observe the instructions provided by the system
manufacturer.
11.2 Filters with a maintenance indicator
(optional)
During cold starts, the maintenance indicator may give a
warning signal (refer to the accessories documentation for
the maintenance indicator).
Do not depress the red button of the maintenance
indicator until operating temperature has been reached.
If it immediately pops out again and / or the electrical
signal is not switched off after reaching operating
temperature, the filter element must be replaced.
11.3 Filtration of cooling lubricants
Fine dirt particles can obstruct the parallel unit when
filtering cooling lubricants.
Operate the parallel unit regularly, even if the
maintenance indicator has not tripped.
12 Troubleshooting
Fault
Possible cause
Remedy
Warning signal
from
maintenance
indicator
Cold start
Reset the signal
after reaching
operating
temperature
Filter element dirty
Replace the filter
element
13 Maintenance
CAUTION!
Danger if unauthorised work is carried out on the
unit!
Risk of injury.
All maintenance work must be carried out by a suitably
trained person.
13.1 Maintenance work on the parallel unit
Shut down the duplex filter.
Take steps to prevent the system from being switched
on again by unauthorised persons.
Take any necessary safety precautions (protective
clothing, eye protection, etc.).
Carry out the maintenance work.
Start up the duplex filter again.
Observe the duplex filter.
Does it operate normally?

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Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
13.2 Maintenance work on the duplex filter
1
The flow direction is indicated by the
pictogram on the switch-over handle (refer to
Figure 5).
Operate the switch-over handle (5) and shift it to the
required position:
- Switch-over handle in position A: filter 1 (F1) is
deactivated while filter 2 (F2) is activated.
- Switch-over handle in position B: filter 2 (F2) is
deactivated while filter 1 (F1) is activated.
- The switch-over handle indicates the deactivated filter.
- Switch-over handle in position C: fluid flows through
both filters (F1 and F2).
Fig. 5: Switch-over handle positions
Make sure the switch-over handle (5) is set to the
required position, so that it contacts the stop and is
locked correctly by the safety catch.
The filter side on which the element must be replaced is
sealed off.
CAUTION!
Danger: Corrosive liquids!
Never operate the switch-over handle while carrying
out maintenance work!
Wear protective clothing and equipment appropriate to
the hazard potential of the medium (e.g. eye protection,
respirator, protective clothing, etc.).
2
Place a trough or a drip pan underneath the unit.
Open the vent screw (2) at least one turn.
3
Open the drain plug on the dirty side (7) (if any).
The filter is drained.
Fig. 6: Draining the filter
5
Carry out the maintenance work.
Check the seals at the drain plug and the vent screw (if
any) and if necessary replace.
6
Screw in the drain plug (if any, torque: 30 Nm).
7
Operate the switch-over handle and shift it to the middle
position.
Tighten the vent screw as soon as fluid exits from the
vent hole without any bubbles (torque: 25 Nm).
Check that the filter is tight.
8
Make sure the switch-over handle contacts the stop and
is locked by the safety catch, so that the filter side that is
being maintained is deactivated (as indicated by the
pictogram on the handle).
Observe the duplex filter.
Does it operate normally?
A
C
B
F1 F2
1
5
2
7

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Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
13.3 Inspection and maintenance schedule
•Refer also to the contract documentation.
The inspection and maintenance schedule should be
fixed individually by the owner.
•Maintenance and monitoring of the filter
must be carried out as required by law and
local regulations.
•A visual inspection is recommended
whenever the filter element is replaced or
every six months at the latest.
•Carry out maintenance once a year.
The necessary inspection and maintenance
work is dependent on the particular
application.
Please consult the system manufacturer if
necessary.
13.4 Replacing the filter element
DANGER!
The filter is pressurised!
First relieve the pressure!
Then open the filter!
DANGER!
Risk of injury!
The element is only allowed to be replaced on the
non-operational filter side.
CAUTION!

Keep all impurities away from the clean side of the
filter element.
Be careful not to damage the wire cloth of the element
or the inside with sharp or pointed objects.
1
The direction of fluid flow is determined by the
position of the marking on the switch-over
handle (refer to Figure 7).
Operate the switch-over handle (5) and shift it to the
required position:
- Switch-over handle in position A: filter 1 (F1) is
deactivated while filter 2 (F2) is activated.
- Switch-over handle in position B: filter 2 (F2) is
deactivated while filter 1 (F1) is activated.
- The switch-over handle indicates the deactivated filter.
- Switch-over handle in position C: fluid flows through
both filters (F1 and F2).
Fig. 7: Switch-over handle positions
Make sure the switch-over handle (5) is set to the
required position, so that it contacts the stop and is
locked by the safety catch.
The filter side on which the element must be replaced is
sealed off.
CAUTION!
Danger: Corrosive liquids!
Never operate the switch-over handle while carrying
out maintenance work!
Wear protective clothing and equipment appropriate to
the hazard potential of the medium (e.g. eye protection,
respirator, protective clothing, etc.).
2
Place a trough or a drip pan underneath the unit.
Open the vent screw (2) at least one turn.
3
Open the drain plug on the dirty side (7) (if any).
The filter is drained.
Fig. 8: Draining the filter
4
Unscrew the filter housing (6) clockwise.
Pull the filter housing down a hand’s breadth.
Unscrew the filter element (12) from the seat.
Remove the filter element together with the filter
housing.
A
C
B
F1 F2
1
5
2
6
7
12

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Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
Fig. 9: Removing the filter element
5
Check all sealing points and seals.
Replace the seals if necessary.
Oil the O-rings using a suitable lubricant.
Replace dirty disposable filter elements with new FG
elements (the order number on the name-plate must
match the order number on the element).
Clean the dirty wire cloth filter element (refer to section
13.6).
6
Carefully position the open side of the filter element in
the seat.
Clean and oil the thread of the filter housing using a
suitable lubricant.
Place the filter housing in position, then screw it on anti-
clockwise as far as possible (torque for NG 300: 100
Nm).
7
Screw in the drain plugs (if any, torque: 30 Nm).
8
Operate the switch-over handle and shift it to the middle
position.
Tighten the vent screw as soon as fluid exits from the
vent hole without any bubbles (torque: 25 Nm).
Check that the filter is tight.
9
Make sure the switch-over handle contacts the stop and
is locked by the safety catch, so that the filter side that is
being maintained is deactivated (as indicated by the
pictogram on the handle).
After starting up one filter side, check that
all sealing points are tight.
Observe the duplex filter.
Does it operate normally?
13.5 Cleaning the filter housing
Wear protective clothing and equipment appropriate to
the hazard potential of the medium (e.g. eye protection,
respirator, protective clothing, etc.).
Open the filter and remove the filter element (refer to
section 13.4).
Remove any coarse impurities by mechanical means.
Wash out the filter housing using a suitable cleaning
solution.
13.6 Cleaning the wire cloth elements
Only wire cloth elements can be cleaned.
Disposable filter elements (PS / MIC /
SMX) must be exchanged and disposed of
correctly.
After starting up one filter side, check that
all sealing points are tight.
Defective seals must be replaced.
The system can never be cleaned one
hundred percent. The service life of the
filter elements is gradually shortened.
Ultrasonic cleaning
Immerse dirty filter elements upright in an ultrasonic
bath for approximately 90 to 120 minutes (turn over if
necessary).
Rinse the filter element in clean cleaning solution (e.g.
naphtha).
Carefully blow out the filter element with compressed air
from the clean side to the outside.
Manual cleaning
Required for filter ratings coarser than 40 μm.
Remove coarse, external impurities with a brush dipped
in cleaning solution (e.g. naphtha).
Leave the filter element to stand for approximately 20
minutes in clean cleaning solution.
Then rinse it with cleaning solution from the clean side
to the outside.
Carefully blow out the filter element with compressed air
from the clean side to the outside.
12
6

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Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
14 Assembly drawing
Fig. 10: Assembly drawing 1/2

Page 12
Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
Fig. 11: Assembly drawing 2/2

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Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
15 Options table
Fig. 12: Dimensions

Page 14
Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
Model
NG
A
B
C
D
E*
F
G
H
øI
J*
K
øL
M
Pi
21430
300 284 132 407 465 110 136 a/f 30
G 1½ 65 2±0.5
49 121.5 210
Pi
21430
FL
- - -
Model NG N O P Q R S T U øV W X Y
Weight
[kg]
Pi
21430
300 62 31 136 167 28 M12x18 66 159
- - - -
Approx.
27
Pi
21430
FL
38 69.9 35.7 M12x21
E* – Clearance required to replace elements
J* – Threaded version only

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Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
16 Spare parts drawing
Fig. 13: Spare parts drawing

Page 16
Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
17 Recommended spare parts and accessories
No. Benennung Material
no.
Designation
1-7
Dichtungssatz für Pi 21430
Seal kit for Pi 21430
NBR
72464282
NBR
FKM
72464283
FKM
EPDM
72464284
EPDM
8-9
Dichtungssatz für Wartungsanzeiger
Seal kit for maintenance indicator
NBR
77760309
NBR
FKM
77760317
FKM
EPDM
77760325
EPDM
11
Wartungsanzeiger
Maintenance indicator
Optisch PiS 3098/2.2
77669971
Visual PiS 3098/2.2
Elektrisch PiS 3097/2.2
77669948
Electrical PiS 3097/2.2
Nur elektrisches Oberteil
77536550
Only electrical cover

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Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
18 Negative declaration

Page 18
Translation of the original instructions with installation instructions Pi 214, Filtration Group GmbH, 16.01.19, Mat. No. 72464269, Version 00
19 Index
E
Environmental protection ................................................... 3
F
Filter element....................................................... 4, 6, 9, 10
Filter housing ........................................................... 5, 9, 10
L
Leakage............................................................................. 2
M
Manufacturer...................................................................... 2
P
Pressure relief.................................................................... 6
Protective clothing and equipment........................... 8, 9, 10
R
Risks...................................................................................2
S
Safety instructions ..............................................................2
Seat..............................................................................9, 10
Space for removal ..............................................................6
Switch-over handle...........................................5, 7, 8, 9, 10
V
Vent screw..........................................................................5
W
Warning ..............................................................................2

Filtration Group GmbH
Schleifbachweg 45
D-74613 Öhringen
Phone [phone]
Fax [phone]
fm.de.s[email protected]
www.industrial.filtrationgroup.com
72464269.I00.01/2019