Translation of The Original Instructions With Installation Instructions

Translation of the original instructions with installation instructions
UG 54
Double filter
Mat. No. of original instructions

70580780
1 Table of contents 2 General safety instructions
1 Table of contents ....................................................... 2 2.1 Safety instructions for installation and
2 General safety instructions ....................................... 2 operating personnel
2.1 Safety instructions for installation and This Instruction Manual contains important safety
operating personnel .......................................... 2 instructions which must be heeded at all times during
2.2 Warning structure.............................................. 2 installation, normal operation and maintenance.
2.3 Warning symbols used ...................................... 2 Non-observance can result in the following risks to persons
2.4 Other symbols used .......................................... 3 and the environment as well as in damage to the machine or
3 Glossary ...................................................................... 3 plant:
4 General information ................................................... 3 Ö Failure of critical functions of the machine or plant or of
4.1 Manufacturer ..................................................... 3 its component parts.
4.2 Information about the Instruction Manual .......... 3 Ö Danger to persons from electrical or mechanical effects
as well as from chemical reactions.
5 Intended application .................................................. 3 Ö Danger to the environment owing to the leakage of
6 Functional description ............................................... 4 hazardous substances.
6.1 Main components.............................................. 4
6.2 Operating principle ............................................ 4 Before installation/start-up:
7 Technical data ............................................................ 4 y Read the Instruction Manual carefully.
7.1 General data ..................................................... 4 y Make sure that installation and operating personnel are
7.2 Mounting parts .................................................. 4 adequately trained.
7.3 Filter insert ........................................................ 4 y Make sure the contents of the Instruction Manual are fully
7.4 Operating data .................................................. 4 understood by the responsible persons.
y Define areas of responsibility and competence.
8 Transport and storage ............................................... 4
y Prepare a maintenance schedule.
8.1 Transport .......................................................... 4
8.2 Storage ............................................................. 4
During operation of the plant:
9 Installation istructions ............................................... 5 y Keep the Instruction Manual handy at the place of use.
10 Start-up ....................................................................... 5 y Heed the safety instructions. Always operate the
10.1 Functional test................................................... 5 machine/plant in accordance with its ratings.
10.2 Start-up ............................................................. 5
11 Normal operation ....................................................... 5 If in doubt:
11.1 Change-over procedure .................................... 5 y Consult the manufacturer.
12 Shutting down the double filter ................................ 6 2.2 Warning structure
12.1 Temporary shut-down ....................................... 6 Where possible, warnings are structured according to the
12.2 Prolonged shut-down (>48 h)............................ 6 following system:
12.3 Emergency shut-down ...................................... 6 Signal word
13 Troubleshooting ......................................................... 6 Nature and source of the danger
Possibly
14 Maintenance ............................................................... 6 Ö Potential consequences of non-
with
14.1 Inspection and maintenance schedule .............. 6 symbol
observance
14.2 Preliminary maintenance steps ......................... 7 y Action to avert the danger.
14.3 Removing the filter insert .................................. 7 2.3 Warning symbols used
14.4 Cleaning double filter and filter insert ................ 7
14.4.1 Cleaning the filter housing ..................... 7 DANGER!
14.5 Replacing the cover seal ................................... 7 Immediate danger!
14.6 Replacing the O-rings on the plug..................... 8 Ö Non-observance will result in serious or fatal injury.
15 Dimension drawings .................................................. 9 WARNING!
15.1 Dimension drawings of the UG 54 .................... 9
Potentially dangerous situation!
16 Part drawing ............................................................. 10 Ö Non-observance can result in serious or fatal injury.
17 Part list ...................................................................... 11
18 Recommended spart parts ...................................... 12 CAUTION!
17 Declaration of incorporation ................................... 13
Ö Non-observance can result in minor or moderate
18 Declaration of conformitiy ....................................... 14 injuries.
19 Index .......................................................................... 15 CAUTION! (without a symbol)
Ö Non-observance can result in property damage.
Page 2
Translation of the original instructions with installation instructions UG 54, MAHLE Industriefiltration GmbH, 18.04.2013 Mat. No. 70580780, Version 01
2.4 Other symbols used Suspension (raw suspension):
System of substances that must be filtered, generally
consisting of solids in a liquid.
Information about environmental protection
4 General information
4.1 Manufacturer
Wear protective clothing! MAHLE Industriefiltration GmbH
Schleifbachweg 45
D-74613 Öhringen
Phone: +49 0 7941 67-0
Fax: +49 0 7941 67-23429
Wear goggles!
4.2 Information about the Instruction Manual
MAHLE Mat.-Nr.: ................................................. 70580780
Date: .................................................................... 18.04.13
Wear a respirator! Version: .......................................................................... 01
5 Intended application
Hand symbol: DANGER!
Indicates general information and PROHIBITED:
recommendations y Use for purposes other than that described below
without prior consultation with the manufacturer.
Bullet:
y Use in potentially explosive atmospheres.
y Indicates the order in which
y Use with smouldering, burning or adhesive particles.
actions are to be carried out
y Use with highly explosive dusts (e.g. aluminium dust,
explosives, etc.).
Arrow:
Ö CAUTION!
Indicates responses to actions
This double filter is only allowed to be used in
accordance with the operating conditions specified in the
contract documentation and in the Instruction Manual. All
3 Glossary forms of use which deviate from or exceed the limits of
use described above are considered to be contrary to the
Absolute filter rating: intended purpose. The manufacturer shall not be liable
The diameter of the largest spherical particle that will pass for any damage resulting from such use.
through the filter under defined laboratory conditions.
Initial differential pressure:
Differential pressure at the start of the filtration process
(when the filter insert is "clean").
Differential pressure (delta p):

Pressure difference between the dirty side and
the clean side.
Filter cake:
Layer that is built up by the solids retained on the surface of
the filter insert.
Filtration operating mode:

The double filter is in normal operation with fluid flowing
through one canister.
Filtered fluid:
Substance that is filtered.
Filter insert:
Cylindrical body consisting of one or more profiled bodies
with the corresponding filtration fineness or fitted with wire
cloth. The suspension to be filtered flows through this
(these) profiled body ( bodies ). Solids are retained on the
inner or outer surface of the filter insert.
Nominal filter rating:

A nominated minimum percentage of the particles that are
smaller than the specified rating are retained by the filter.
Page 3
6 Functional description 3
The filtered fluid enters the clean side and exits the double
6.1 Main components filter via the filter outlet.
4
On reaching a differential pressure of 0,7 bar (optional
differential pressure indicator), the filter must be switched
over and the insert cleaned manually. The filtration process
is not interrupted when doing so. Refer to sections
11.1+14.4
7 Technical data
7.1 General data
Filter type .......................................................... Double filter
Series ......................................................................... UG 54
Nominal diameter .......... For dimensions, refer to section 15
Weight ........................... For dimensions, refer to section 15
Filter housing material ................................GGG40 (0.7040)
Change over plug material ........... 0.7040/ 1.4011 (optional)
Coating (outside) .................................................. RAL 5007
Seals .....................................................FPM / NBR / C4400
7.2 Mounting parts

Differential pressure indicator .................................. optional
Fig. 1: Diagram of the main components
1 Filter canister 7.3 Filter insert
2 Filter inlet Number per canister .......................................................... 1
3 Filter outlet Material Filter screen …………………………………..1.4401
4 Differential pressure indicator/switch (optional) Material body .................................................. Steel /1.4571
5 Change over lever Filter rating ........................... Acc. to customer specification
6 Vent screw
7 Filter insert 7.4 Operating data
8 Drain Capacity ................................................................... unknow
Medium .................................................................... unknow
6.2 Operating principle Canister capacity ................................................ 2x0,8 Liter
Process temperature ........................................... Max. 80°C
Test overpressure ...................................................... 15 bar
Process overpressure ....................................... Max. 10 bar
Pressure loss ................................... Approx. 0.1 bar (clean)
............................................................... Max. 0.7 bar (dirty)
Acceptance Acc. to Pressure Equipment Directive,Art. 3.3
8 Transport and storage

8.1 Transport
y Always transport upright
y Avoid vibrations
8.2 Storage
y Always store upright in the original packaging
y Always store in a dry, frost-free room
Fig. 2: Filtration principle of the double filter

The suspension flows through the filter inlet into the double
filter.
Seaworthy packaging is specified in the
2 contract documentation as an option.
The suspension flows through the interior of the filter insert.
The particles contained in the suspension settle on the
inside of the insert.
In the case of double inserts, also on the outside of the inner
cylinder of the insert.
Page 4
9 Installation istructions
10.2 Start-up
WARNING! CAUTION!
If the system is installed by unauthorised persons High viscosity
Ö Risk of injury Ö Damage to property
y All warranty claims are rendered invalid y If high-viscosity media are used, the filter should not
y The plant must be installed by a suitably trained be start with full power of the pump until the filter
person! reaches its normal service temperature
y Provide stress relief for all pipe connections.
y Make sure the filter does not run dry via the pipes when y Slowly open the inlet.
the plant is not operating. y Vent the double filter with the vent screw (1).
y Pay attention to the direction of flow.
10 Start-up
DANGER!
This double filter is not allowed to be put into operation
until it has been established that the machine / plant in
which it is to be installed complies with the classifications
of the acceptance authority.
DANGER!
Danger due to high pressure in the double filter!
Ö Risk of injury to persons or damage to property
y Do not allow the concentrate to spatter into the
atmosphere!
Make sure that:
Ö All foreign particles are removed from the double filter.
Ö All pipe connections are tightened securely.
Ö All screws are tightened.
10.1 Functional test
Checking the functionality of the change-over unit
y Make sure the pressure compensation line (1) is open Fig. 4: Venting the filter
before initiating the change-over procedure. (DN80 only)
y The filter is switched over to the other filter canister by
turning the change-over lever (2) by 180º. Initial differential pressure
y In its end position, the change-over lever is positioned y The initial differential pressure varies according to the
above the canister which is operation. application.
y Close the pressure compensation line. (DN 80 only) y General guide:
Installation on discharge side: Δp ≤ 0.1 bar
11 Normal operation
DANGER!
Danger due to high pressure in the double filter!
y Do not allow concentrate to spatter into the
atmosphere!
y Always dispose of the flush concentrate in a
manner which does not pollute the
environment or process it professionally!
y Consult the responsible authorities before
deciding upon the most suitable disposal
method.
y The following must be monitored daily during normal
operation:
Ö Differential pressure
Ö Functionality of the change-over unit
Fig. 3: Checking the functionality of the change-over unit 11.1 Change-over procedure
y Change over to the clean filter canister at a differential

pressure 0.7 bar.
y Refer to section 10.1
y Upon completion of the change-over procedure, vent the
canister which is operation.
Page 5
12 Shutting down the double filter 14 Maintenance
12.1 Temporary shut-down WARNING!
y Switch off pumps. If the system is maintained by unauthorised persons
y Filter must not run dry via the pipelines. Ö Risk of injury
y All warranty claims are rendered invalid
12.2 Prolonged shut-down (>48 h) y The system must be maintained by a suitably trained
y Make sure the inlet and outlet are closed. person!
y Remove the filter insert (refer to section 14.3). Before all maintenance work:
y Clean the filter insert (refer to section 14.4). y Shut down the double filter (refer to section 12).
y Reinstall the filter insert. y Take steps to prevent contaminated medium from
y Change-over lever in central position. entering the clean side; discharge the filter via the
y Fill the double filter completely with liquid. discharge screw if necessary.
12.3 Emergency shut-down y Take steps to prevent the double filter from being
y No special steps required. operated again by unauthorised persons.
13 Troubleshooting
Fault Possible Remedy
cause
Change-over Pressure Open pressure
procedure not compensation line compensation line
possible not open
Initial Filter insert dirty Clean filter insert
differential Solids content too manually
pressure no high Suitable pre-
longer attained filtration
Increased Filter insert Check filter insert;
concentration of defective replace if
dirt on the clean necessary
side
Leakage at the Defective O-rings Replace O-rings
plug on plug
y Wear protective clothing and equipment appropriate to

the hazard potential of the medium (e.g. goggles,
respirator, protective clothing, etc.).
y Carry out the maintenance work.
y Start up the double filter again (refer to section 10).
14.1 Inspection and maintenance schedule

y Refer also to the contract documentation.
Interval Component Activity
Daily Change over unit Check functionality
Weekly Double filter Check for leakage
and if necessary
replace the seals
Monthly Filter insert Check for damage
and if necessary
replace
The necessary inspection and maintenance

work is dependent on the particular
application.
Please consult the manufacturer if necessary.
Page 6
14.2 Preliminary maintenance steps
DANGER!
The double filter is pressurised!
y Make sure the pipe is depressurised prior to opening
the double filter.
y Always dispose of the flush concentrate in a
manner which does not pollute the
environment!
y Consult the responsible authorities before
deciding upon the most suitable disposal
method.
1
y Pump off.
2
y Make sure the pipe is depressurised prior to opening the
double filter.
y Close the filter inlet and outlet.
3
y Open the drain plug.
y Open the vent screw.
Ö The double filter is discharged.
Fig. 6: Removing the filter cover and filter insert

3
y Mount in reverse order
14.4 Cleaning double filter and filter insert

y Remove the filter insert. ( Refer to section 14.3)
y Clean the filter insert ( refer to N2552 )
WARNING!
Fig. 5: Preliminary maintenance steps
Danger of aerosol formation!
14.3 Removing the filter insert y All work must be carried out in a room with a suitable
extraction system!
DANGER!
The double filter is pressurised!
Ö Risk of injury to persons or damage to property 14.4.1 Cleaning the filter housing
y Make sure the pipe is depressurised prior to opening
the double filter.
y Carry out the preliminary maintenance steps (refer to
section 14.2).
1 y Wear protective clothing and equipment appropriate to

y Loosen and remove the hexagon nuts on the filter cover. the hazard potential of the medium (e.g. goggles,
respirator, protective clothing, etc.).
2 y Remove any coarse impurities by mechanical means.
y Remove the filter cover. y Wash out the filter housing in a suitable cleaning solution.
y Lift the filter insert vertically out of the filter housing 14.5 Replacing the cover seal
without tilting it.
y Remove the filter cover (refer to section 14.3).
Ö The cover seals can now be replaced
Page 7
14.6 Replacing the O-rings on the plug
WARNING!
If the system is maintained by unauthorised persons:
Ö Risk of injury
Ö All warranty claims are rendered invalid
y The system must be maintained by a suitably trained
person!
y Preliminary maintenance steps (refer to section 14.2)
1. Remove the stop plate.

2. Pull the plug upwards just a bit until the O-ring is
visible.
3. Remove the O-ring.
4. Press the plug ( without the O-ring downwards
until the lower O-ring is visible.
5. Remove the lower O-ring and insert the new,
greased O-ring.
6. Press/pull the plug upwards until the O-ring
groove is visible.
7. Insert the new, greased O-ring.
8. Press the plug back into the operating position.
9. Fix the stop plate.
Fig. 7: Replacing the O-rings on the plug
Page 8
15 Dimension drawings
15.1 Dimension drawings of the UG 54
Fig. 8: Dimension drawing of the UG54
Page 9
16 Part drawing
Fig. 9: Part drawing UG 54
Page 10
17 Part list
Pos. Part name Qty.

1 Housing 1
2 Cover 2
3.1 Plug 1
3.2 Stop plate 1
3.3 Hexagon screw 2
3.4 O-ring 2
4.1 Stud bolt 8

4.1 Hexagon nut 8
4.3 Gasket 2
4.4 Spring 2
4.5 Screw plug 2
4.6 Sealing ring 2
4.7 Screw plug 2
4.8 Sealing ring 2
7 Screw plug 2
8 Sealing ring 2
201 Cock wrench 1
S Insert 1
D Diff. Pressure indicator ( optional ) 1
Page 11
Translation of the original instructions with installation instructions UG 54, MAHLE Industriefiltration GmbH, 18.04.2013, Mat. No. 70580780, Version 01
18 Recommended spart parts
No. Part name Qty. Data sheet

S Insert Rating … mm 2 S3
3.4 O-Ring 2
4.3 Gasket 2
4.4 Spring 2
Please request a separate spare parts drawing and list of spare parts for special versions.
Page 12
17 Declaration of incorporation
Page 13
18 Declaration of conformitiy
Page 14
19 Index
C I
Cleaning the automatic filter .............................................. 7 Initial differential pressure................................................... 3
Concentrate ................................................................... 5, 7 Inlet .................................................................................... 5
Contract documentation ..................................................... 3 Installation on discharge side ............................................. 5
D L
Differential pressure ........................................................... 3 Leakage.............................................................................. 2
Dimension drawing ............................................................ 9
Drain valve ..................................................................... 3, 7 M
Manufacturer .................................................................. 2, 3
E
Environmental protection ................................................... 3 P
Ersatzteile ........................................................................ 12 P3
Preliminary maintenance steps .......................................... 7
F Protective equipment .......................................................... 6
Filter cake .......................................................................... 3
Filter cartridge .................................................................... 4 R
Filter insert ................................................................. 4, 6, 7 Removing the gear motor ................................................... 7
Functional description ........................................................ 4 Replacing the cartridge seals ......................................... 7, 8
Functional test ................................................................... 5 Risks................................................................................... 2
G S
Gear motor......................................................................... 7 Safety instructions .............................................................. 2
Seaworthy packaging ......................................................... 4
Suspension......................................................................... 3
V
Valves................................................................................. 3
W
Warning symbols ................................................................ 2
Page 15
MAHLE Industriefiltration GmbH
Schleifbachweg 45
D-74613 Öhringen
Phone +49 0 7941 67-0
Fax +49 0 7941 67-23429
indutrialfiltration@mahle.com
www.mahle-industrialfiltration.com
70580780.I01.04/2013

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Translation of The Original Instructions With Installation Instructions

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Translation of the original instructions with installation instructions

Mat. No. of original instructions

Differential pressure (delta p):

Filtration operating mode:

Nominal filter rating:

7.2 Mounting parts

8 Transport and storage

Fig. 2: Filtration principle of the double filter

y Change over to the clean filter canister at a differential

y Wear protective clothing and equipment appropriate to

14.1 Inspection and maintenance schedule

The necessary inspection and maintenance

Fig. 6: Removing the filter cover and filter insert

14.4 Cleaning double filter and filter insert

1 y Wear protective clothing and equipment appropriate to

y Preliminary maintenance steps (refer to section 14.2)

1. Remove the stop plate.

Fig. 7: Replacing the O-rings on the plug

Fig. 8: Dimension drawing of the UG54

Fig. 9: Part drawing UG 54

Pos. Part name Qty.

4.1 Stud bolt 8

No. Part name Qty. Data sheet

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