Gardner Denver FIL Series User manual

1
7610.490.52A 6/01
18-5-610
FIL SERIES COMPRESSED AIR FILTERS
MODELS: FIL32 through FIL54
INSTRUCTION MANUAL
General Safety Information
1. Pressurized devices
• Do not exceed maximum operating pressure
indicated on serial number tag.
• Make certain filter is fully depressurized before
servicing.
2. Breathing Air
• Air treated by this equipment may not be suitable
for breathing without further purification. Refer
to OSHA standard 1910.134 for breathing air
requirements.
3. Flammable gases
The materials of construction used in this product are
compatible physically with flammable gases, however,
there are application limitations for this product when
used with flammable gases. Each application (other than
air or inert gas) should be carefully reviewed to minimize
the chances of creating a fire or explosion hazard.
IMPORTANT
Tighten cartridges before use. Cartridges may have
loosened during transit. To ensure a tight seal between
the cartridge end cap(s) and inlet manifold, open vessel
and turn cartridge clockwise (as seen from bottom) until
hand tight. See Section 3.0, B for instructions on
entering vessel.
SERVICE DEPARTMENT: [phone]
Contents
MODEL NUMBER CONFIGURATION .......................... 2
1.0 INSTALLATION ................................................... 3
2.0 OPERATION ....................................................... 5
3.0 MAINTENANCE ................................................. 6
DIMENSIONS AND WEIGHTS..................................... 7
WARRANTY .............................................................. 8

2
Grade Identification
Filter grade can be identified by the third digit of the model number. In addition, elements with a foam outer sleeve can be
identified by color
Grade Description Type Outer foam color
A Water separator Impaction type separator none
B Separator/filter Mechanical separator and 3 micron coalescer none
C General purpose 1 micron coalescer none
D Dry Desiccant Afterfilter 1 micron afterfilter for desiccant dryers none
E High efficiency oil removal filter High efficiency (99.99+%) coalescer Red
F Maximum efficiency oil removal filter Maximum efficiency (99.999+%) coalescer Blue
G Oil vapor removal filter Activated carbon adsorber Green
Model Number Configuration
(2) Filter Grade
A - Water Separator
B- Separator/Filter
C - General Purpose
D- Dry Desiccant Afterfilter
E - High Efficiency Oil Removal Filter
F - Maximum Efficiency Oil Removal Filter
G- Oil Vapor Removal Filter
(3) Connection
Sizes
27 - 3” ANSI Flange
29 - 4” ANSI Flange
31 - 6” ANSI Flange
33 - 8” ANSI Flange
35 - 10” ANSI Flange
FIL (1) (2) (3) (4)
(4) Features
D = Internal Automatic Drain Mechanism
G = Differential Pressure Gauge Indicator
S = Corrosion Proof Stainless Steel Element
M= Element Monitor
1. Housing Number is indicated in space (1).
2. Filter Grade is indicated in space (2).
3. Connection Size is indicated in space (3)
4. If optional corrosion proof stainless steel cores are included,
an Sis indicated in space (4). Corrosion resistant stainless
steel cores are standard.
Example: A Grade E high efficiency oil removal filter with a capacity of
1250 scfm and 3" ANSI Flange connections would be configured
as: FIL36E27G
(1) Housing
Number Capacity
scfm [m
3
/hr] @
100 psig [7 kgf/cm2]
32 625 [1110]
34 1000 [1700]
36 1250 [2125]
38 1875 [3158]
40 2500 [4250]
42 3125 [5310]
44 5000 [8490]
46 6875 [11,670]
48 8750 [14,850]
50 11875 [20,175]
52 16250 [27,610]
54 21250 [36,100]
n

3
1.0 Installation
A. Where Used/Air Quality After Filtration
Grade Where used Solid particle Liquid removal Maximum inlet Remaining oil
removal (maximum efficiency (at rated liquid loading content
size in microns) conditions) ppm w/w ppm w/w
A Separator - downstream of an aftercooler
Point-of-use - where no aftercooler is installed
upstream
B Separator - downstream of an aftercooler
Point-of-use - where no aftercooler is installed
upstream or as prefilter to refrigerated dryer
C Prefilter -
•Prefilter to Grade F & Grade E high efficiency filters
Point-of-use - where aftercooler is installed upstream
D Afterfilter- downstream of a pressure-swing (heatless
desiccant dryer
•Downstream of an Activated Carbon or Desiccant
Tower
E Prefilter - ahead of desiccant and membrane dryers
Afterfilter
•Downstream of refrigerated dryer
•Downstream of pressure-swing (heatless)
desiccant dryers for finer solid particle removal
•Oil removal at point-of-use
F Prefilter - ahead of desiccant and membrane
dryers (use after Grade C to reduce liquid and solids
load, prolong element life and ensure filtration
efficiency)
Afterfilter - downstream of refrigerated dryer
G Afterfilter to Grade E & Grade F for true oil free
applications
--- 95% of water 30,000 ---
bulk liquids
3 99+% of water 25,000 5
aerosols &
bulk liquids
1 100% of water 2,000 1
aerosols aerosols
) 1 No liquid should be No liquid should be
present at inlet present at inlet ---
0.01 99.99+% of oil 1,000 0.008
aerosols aerosols
0.01 99.999+% of oil 100 0.0008
aerosols aerosols
0.01 Removes vapors only No liquid should 0.003
be present vapor
B. Piping
1. Before installing, blow out pipe line to remove scale
and other foreign matter.
2. Mounting (Grades A, B, C, E, F) - mount so that inlet
and outlet connections are horizontal (filter bowl
vertical) to ensure proper liquid drainage.
3. Flow Direction - install so that the air flow is in the
direction indicated on filter.
NOTE: Grade D flows from outside to inside of element.
All other grades flow from inside to outside. Observe
flow arrows on unit.
4. Isolation valves and by-pass piping - For ease of
service, isolation and by-pass valves are desirable. In
critical applications, two filters installed in parallel may
be necessary to avoid interruption of air supply.
C. Drain Provisions (Grades A, B, C, E, F) - The bottom of
the pressure vessel is provided with a drain plug for
shipping purposes. Provision for manual or automatic
draining is necessary for proper operation.
Do not attempt to remove drain plug if
the unit is pressurized.
1. Manual Drain - When draining is performed manually
on a regular, periodic basis, a simple (open/shut) valve
may be used to drain the vessel. When draining
manually, the valve should be opened slowly to avoid
rapid depressurization and possible element damage.
2. Automatic Drain - Where regular manual draining is
not performed, an automatic condensate drain
should be used. A variety of drains is available from
the manufacturer.
SMD MODELS TMD MODELS
1" DRAIN PORT
FILTER
HOUSING
MANUAL
OVERRIDE
22
MIN
SEC
1
7
15
145
POWER
ON
ELECTRIC DRAIN

4
D. Differential Pressure Gauge (DPG) - Grades B, C, D, E, F
On standard units, a gauge and installation kit are
shipped separately packaged for field installation. Refer
to diagram for proper installation. Gauge may be
installed on filter housing or on a nearby wall using the
wall mounting bracket supplied.
NOTES:
1) Make certain o-rings are in place on the bottom of
the gauge body.
2) Connect the low pressure transmission bolt (bolt
next to RED band on gauge) to the gauge port at
the filter outlet (down-stream side of filter).
3) Connect the high pressure transmission bolt (bolt
next to GREEN band on gauge) to the gauge port at
the filter inlet (upstream side of filter).
4) Torque bolts to 25 +/- 5 inch oz. A flathead screwdriver
with a 3/8” (1 cm) minimum blade width can be used
to assemble/diassemble the gauge. Small blade widths
will damage the bolt heads.
DO NOT OVER TIGHTEN
Model 32 - Equipment Mounted
All Models - Wall Mounted
Model 34 and Larger - Equipment Mounted
INLET OUTLET
O-RINGS
WALL
INLET OUTLET
O-RINGS

5
2.0 Operation
Do not operate filter at pressures in excess of
Maximum Working Pressure indicated on Serial Number Tag.
NOTE: Maximum Operating Temperature - 150°F, 66°C.
Liquid filtration above 120°F, 49°C is not recommended since
there is typically oil present in a vapor state which passes
through the filter and condenses downstream.
NOTE: Grade G - If operated above 100°F, 38°C, a Grade 1
filter may experience less than 1000 hours of life because
of greater oil vapor content.
A. Operational Checkpoints
Grades A, B, C, D, E, F
1. Grades B, C, D, E, F - Check pressure drop across
the filter
a. Pressure differential in excess of 6 psi (0.42 kgf/cm2) -
pressure indicator in red area - indicates that the filter
sleeve or element should be replaced.
NOTE: Element should be changed annually or when
indicator changes to red, whichever occurs first.
NOTE: Pressure drop should never exceed 15 psi
(1.0 kgf/cm2).
NOTE: Grades B, C, E, F - Pressure drop may temporarily
increase when flow is resumed after flow stoppage. Pres-
sure drop should return to normal within one hour.
b. Check for sudden reduction in pressure drop. This
might indicate:
(1) Possible leak across element o-ring seal
(2) Leak through the element due to physical
damage
2. Check flow, pressure, and temperature to make
certain filter is being operated within design condi-
tions.
3. Grades A, B, C, E, F - Check to see that filter is
installed level to insure proper drainage.
4. Grades A, B, C, E, F - Check that manual drains are
drained periodically or that automatic drains are
functioning.
Grade G
1. Check for an oily smell by opening the manual valve. If
an oily smell exists, the following should be checked:
a. Filter element adsorption capacity exhausted
b. Leak across element o-ring seal
c. Leak through element due to physical damage
d. Presence of liquids because of lack of or failure of
prefilters
e. Flow, pressure and temperatures outside design
conditions
f. Presence of gaseous impurities which cannot be
adsorbed by activated carbon
Methane, carbon monoxide, carbon dioxide
and various inorganic gases cannot be removed by a Grade 1
filter.
C. Flow Capacity
Maximum air flow for the various filters at 100 psig
(7 kgf/cm2) is indicated in Table 1. To determine maximum air
flows at inlet pressures other than 100 psig
(7 kgf/cm2), multiply flow from Table 1 by air flow correction
factor from Table 2 that corresponds to the minimum
operating pressure at the inlet of the filter.
NOTE: Filters should not be selected by pipe size. Select
using flow rate and operating pressure only.
Table 1 - Maximum Flow @100 psig [7 kgf/cm2]
Housing scfm [m
3
/hr]
32 625 [1110]
34 1000 [1700]
36 1250 [2125]
38 1875 [3158]
40 2500 [4250]
42 3125 [5310]
44 5000 [8490]
46 6875 [11,670]
48 8750 [14,850]
50 11875 [20,175]
52 16250 [27,610]
54 21250 [36,100]
Minimum
Inlet
Pressure
Table 2 - Air Flow Correction Factor
psig 20 30 40 60 80 100 125 175 150 200 250 300
kgf/cm21.4 2.1 2.8 4.2 5.6 7.0 8.8 12.3 10.6 14.1 17.6 21.1
Correction Factor 0.30 0.39 0.48 0.65 0.82 1.00 1.22 1.65 1.43 1.87 2.31 2.74
Minimum
Inlet
Pressure
psig 350 400 450 500 550 600 650 700
kgf/cm224.6 28.1 31.6 35.2 38.7 42.2 45.7 49.2
Correction Factor 3.18 3.62 4.05 4.49 4.92 5.36 5.80 6.23
n

6
5. Grades B, C, D, E, F, G - Discard old elements and o-rings.
6. Clean inlet manifold with a mild
detergent using a long-handled
brush or clean rag attached to a
rod. Manifold must be free of
all dirt and grease to insure
proper o-ring seal between
new filter element top cap
and inlet manifold.
7. Install new o-rings in the
o-ring grooves in each filter
element.
8. Starting from the outside
(filter element closest to the
vessel wall), screw new filter
elements into inlet manifold
connections. A cone in the
manifold will guide the
element bolt into the female
threads.
NOTE: Grades E, F and G - Do not handle elements by outside
foam cover. Handle by plastic packaging and bottom end
cap only.
NOTE: It is only necessary to finger tighten the filter
element to insure a seal. DO NOT WRENCH TIGHTEN
9. Close vessel
9A. Model 32 - Reassemble bottom shell, o-ring and seal-
ring retainer to housing. Make sure seal-ring retainer
provides a backup for the o-ring as shown in drawing.
9B. Models with hand hole
a. Reinsert seal plate and seal plate gasket into vessel
and position on lip as shown in drawing.
NOTE: Do not reuse gasket if gasket is torn or gasket surface
is damaged.
b. Reinstall yoke and nut.
c. Tighten nut making sure that gasket is properly
positioned under seal plate.
9C. Models with flanged bottom
a. Swing blind bottom flange into position.
b. Rebolt after inspecting flange gasket to ensure its
integrity.
10. Pressurize unit slowly by slowly opening inlet valve,
then opening outlet valve, and finally closing by-pass
valve.
3.0 Maintenance
A. When to Replace Filter Element
NOTE: Grades B, C, D, E, F, G - complete element is replaced:
1. Grades D (dry desiccant afterfilter)
Initial drop: 1 psi (0.07 kgf/cm2). Pressure drop increases
as element loads with solid particles. Replace when
pressure drop reaches 10 psi (0.7 kgf/cm2) (indicator in
red area) or annually, whichever occurs first.
2. Grade A (mechanical separator)
Element should not require replacement unless physically
damaged. If sludge accumulates, element can be
removed and cleaned with soap and water.
3. Grades B, C, E, F (coalescing filters)
a. Initial (dry) pressure drop: 1 psi (0.07 kgf/cm2) to 2 psi
(0.14 kgf/cm2)
b. Operating pressure drop: As filter becomes liquid
loaded (wetted), pressure drop will increase to 2 to
6 psi (0.14 to 0.42 kgf/cm2). Further pressure drop
occurs as element loads with solid particles.
FOR MAXIMUM FILTRATION EFFICIENCY, REPLACE ELEMENT
WHEN PRESSURE DROP REACHES 6 PSI (0.42 KGF/CM2)
(INDICATOR IN RED AREA) OR ANNUALLY, WHICHEVER OCCURS
FIRST.
NOTE: Pressure drop may temporarily increase when flow is
resumed after flow stoppage. Pressure drop should return
to normal within one hour.
NOTE: Grades E and F - During normal operation bottom of
foam sleeve will have a band of oil. Spotting above the band
indicates that liquids are accumulating faster than they can
be drained and that prefiltration is required.
4. Grade G (activated carbon filters)
a. Adsorption capacity - 1000 hours at rated capacity.
Element life is exhausted when odor can be detected
downstream of the filter.
B. Procedure for Element Replacement
THIS FILTER IS A PRESSURE CONTAINING
DEVICE. DEPRESSURIZE BEFORE SERVICING.
1. By-pass the filter to permit
servicing.
2. Depressurize the filter assembly
slowly by opening blowdown
valve.
3. Open pressure vessel
3A. Model 32 - Remove flange bolts.
Lower bottom shell, o-ring, and seal
ring retainer.
3B. Models with handhole
a. Remove nut and yoke
b. Lift seal plate and turn so that seal plate and seal
plate gasket can be removed.
3C. Models with flanged bottom
a. Loosen bottom blind flange bolts.
b. Remove all but one bolt.
c. Swing flange to one side.
4. Starting in the center, unscrew the filter elements
and remove the filter elements and element
o-rings.
Bottom Flange
O-RING
PLASTIC
SEAL RING
RETAINER
LOWER
BOTTOM
OF SHELL
All Grades -
Element Replacement
SEAL PLATE
VESSEL
YOKE
NUT
GASKET
TILT THE SEAL PLATE
AND GASKET TO FIT IN OPENING
HAND HOLE
Handhole
Model 32
CONE
INLET
MANIFOLD
O-RINGs
CARTRIDGE
—

7
Dimensions and Weights
Standard
Models FIL32(Grade)27 FIL32(Grade)27-D FIL34(Grade)27 FIL36(Grade)27 FIL38(Grade)27 FIL40(Grade)29 FIL42(Grade)29 FIL44(Grade)31 FIL46(Grade)31 FIL48(Grade)31 FIL50(Grade)33 FIL52(Grade)33 FIL54(Grade)35
Connection 3" NPT 3" NPT 3" NPT 3" NPT 3" NPT 4" ANSI Flg. 4" ANSI Flg. 6" ANSI Flg. 6" ANSI Flg. 6" ANSI Flg. 8"ANSI Flg. 8"ANSI Flg. 10" ANSI Flg.
Maximum Working Pressure 300 psig 300 psig 225 psig 225 psig 225 psig 225 psig 225 psig 225 psig 225 psig 225 psig 225 psig 225 psig 225 psig
Maximum Working Pressure 21.0 kgf/cm
2
21.0 kgf/cm
2
15.8 kgf/cm
2
15.8 kgf/cm
2
15.8 kgf/cm
2
15.8 kgf/cm
2
15.8 kgf/cm
2
15.8 kgf/cm
2
15.8 kgf/cm
2
15.8 kgf/cm
2
15.8 kgf/cm
2
15.8 kgf/cm
2
15.8 kgf/cm
2
No. of Elements FIL32 (Grade)E 1 1 2(1)2 3 4 5 8 11141926 34
Models 32-27 34-27 38-27 40-29 44-31 46-31 50-33 52-33 54-35
Dimensions in (mm) 32-27-D(2) 36-27 42-29 48-31
“A”w/thread 10.25 (260) 16.00 (406) 16.25 (413) —————
“A”w/flange 10.63 (290) 16.38 (416) 16.63 (423) 20.00 (508) 24.00 (610) 28.00 (711) 33.00 (838) 39.00 (991) 45.88 (1165)
“B”40.88 (1038) 48.00 (1219) 49.00 (1245) 52.25 (1327) 54.63 (1387) 62.56 (1589) 69.13 (1756) 67.94 (1726) 70.94 (1802)
“C”4.88 (124) 9.69 (246) 9.69 (246) 11.63 (295) 13.44 (341) 16.88 (429) 19.63 (498) 19.56 (497) 21.56 (548)
“D”32.25 (819) 38.31 (973) 39.31 (999) 40.63 (1032) 41.19 (1046) 45.69 (1160) 49.50 (1257) 48.38 (1229) 49.38 (1254)
Weight lb (kg)
w/thread 36 (14) 90 (41) 118 (54) ——————
w/flange 52 (21) 106 (48) 134 (61) (3) 271 (123) (4) 709 (322) 918 (416) 1412 (640)
Drain Connection 1/2" 1" 1" 1" 1" 1" 1" 1" 1"
Vessel Type I IVIVIV IVIVIVIVIV
NOTE: Dimensions and Weights are for reference only. Request certified drawings for construction purposes.
(1) Use FIL34(Grade)E Elements for FIL34(Grade)27 Filters.
(2) D signifies internal auto drain. Add 1.5 in. (38 mm) to dim. B and 3 lb (1.4 kg) to weight.
(3) 40-29: 178 (81); 42-29: 180 (82);
(4) 46-31-22: 693 (314); 48-31-22: 700 (318).
SERVICE CLEARANCE
24" (610mm)
DRAIN
D
B
C
A
TYPE IV
A w/Flg.
A
Optional
Internal
Auto Drain
SERVICE CLEARANCE
24" (610mm)
DB
C
A w/Flg.
TYPE I

8
SERVICE DEPARTMENT: [phone]
WARRANTY
The manufacturer warrants the product manufactured by it, when properly installed, operated, applied, and maintained in
accordance with procedures and recommendations outlined in manufacturer’s instruction manuals, to be free from defects
in material and workmanship for a period of one (1) year from date shipment to the buyer by the manufacturer or
manufacturer’s authorized distributor provided such defect is discovered and brought to the manufacturer’s attention within
the aforesaid warranty period.
The manufacturer will repair or replace any product or part determined to be defective by the manufacturer within the
warranty period, provided such defect occurred in normal service and not as a result of misuse, abuse, neglect or accident.
Normal maintenance items requiring routine replacement are not warranted. The warranty covers parts and labor for the
warranty period. Repair or replacement shall be made at the factory or the installation site, at the sole option of the manu-
facturer. Any service performed on the product by anyone other than the manufacturer must first be authorized by the
manufacturer.
Unauthorized service voids the warranty and any resulting charge or subsequent claim will not be paid.
Products repaired or replaced under warranty shall be warranted for the unexpired portion of the warranty applying to the
original product.
The foregoing is the exclusive remedy of any buyer of the manufacturer’s product. The maximum damages liability of the
manufacturer is the original purchase price of the product or part.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER WRITTEN, ORAL, OR STATUTORY,
AND IS EXPRESSED IN LIEU OF THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS FOR A
PARTICULAR PURPOSE. THE MANUFACTURER SHALL NOT BE LIABLE FOR LOSS OR DAMAGE BY REASON OF STRICT LIABILITY IN TORT
OR ITS NEGLIGENCE IN WHATEVER MANNER INCLUDING DESIGN, MANUFACTURE OR INSPECTION OF THE EQUIPMENT OR ITS
FAILURE TO DISCOVER, REPORT, REPAIR, OR MODIFY LATENT DEFECTS INHERENT THEREIN.
THE MANUFACTURER, HIS REPRESENTATIVE OR DISTRIBUTOR SHALL NOT BE LIABLE FOR LOSS OF USE OF THE PRODUCT OR OTHER
INCIDENTAL OR CONSEQUENTIAL COSTS, EXPENSES, OR DAMAGES INCURRED BY THE BUYER, WHETHER ARISING FROM BREACH OF
WARRANTY, NEGLIGENCE OR STRICT LIABILITY IN TORT.
The manufacturer does not warrant any product, part, material, component, or accessory manufactured by others and sold
or supplied in connection with the sale of manufacturer’s products. 1/96
AUTHORIZATION FROM THE SERVICE DEPARTMENT IS NECESSARY BEFORE MATERIAL IS
RETURNED TO THE FACTORY OR IN-WARRANTY REPAIRS ARE MADE.
©2001 Gardner Denver, Inc.
http://www.gardnerdenver.com [email protected]
18-5-610 Litho in U.S.A.
For additional information contact
your local representative or
Gardner Denver Compressor and Pump Division,
1800 Gardner Expressway, Quincy, Illinois 62301
Customer Service Department Telephone:
[phone] FAX: [phone]
Sales and Service in all major cities.
For parts information, contact Gardner Denver,
Master Distribution Center, Memphis, TN
Telephone: [phone] FAX: [phone]
Member