MA-PQP-PQ-MAN-037 C OFFSHORE 31 DOCUMENTO CONTROLADOTable of Contents 4 Mechanical equipment 41 List of mechanical equipment CASCADE/ MAN 42 Heat data for cooling water systems MAN 43 Engine cooling and sypply systems 4.3.0 General safety notes MAN Lubrication oil system MAN Fuel oil system MAN Cooling water system MAN Steam and condensate system MAN 4.3.6 Exhaust gas system MAN 4.3.7 Starting air- control air - working air system MAN 44 Auxiliary systems for barge operation 441 Ballast system CASCADE 442 Fresh water system CASCADE 4.4.3 Domestic hot and cold water system CASCADE 44.4 Black and grey water system CASCADE 4.4.5 Sewage system CASCADE 44.6 Fire fighting system CASCADE 44.7 Ventilation system CASCADE 4.4.7-1 Ventilation of main engine hall CASCADE 4.4.7-2 Ventilation of separator room CASCADE 4.4.7-3 Ventilation of forward pump room CASCADE 4.4.7-4 Ventilation of aft pump room CASCADE 4.4.7-5 Deckshouse ventilation CASCADE 4.4.7-6 Alternator exhaust system CASCADE 4.4.8 Air conditioning system CASCADE 44.9 Oily water, dirty oil and sludge system CASCADE 45 Other systems 45.1 Communications system CASCADE 45.2 Alarm system CASCADE 4.5.3 Tank vents CASCADE 4.5.4 Sounding tubes CASCADE 45.5 Safety systems | CASCADE 4.5.5-1 Fire detection system CASCADE 4.5.5-2 __| General alarm system CASCADE 4.5.5-3 CO,/Ventilation shut down system CASCADE 45.6 Wireway system arrangements CASCADE 4.5.7 Exterior deck drains CASCADE POWER BARGE Drafted: 31.08.1999 Revision: 01.08.00 Page 1/9 ESPERANZA TAT/TKU TKUMAN Intake Air System Cc 4.3.5 Table of Contents: 4.3.5 -1 Safety regulations 4.3.5 -2 System description 4.3.5 - 2.1 Overview 4.3.5-2.2 Negative static pressure (suction pressure) 4.3.5 - 2.3 Oil-bath circulating filter 7 4.3.5 - 2.3.1 Main components of the oil-bath circulating filter 4.3.5-2.4 Intake air muffler 4.3.5 - 2.5 Fixed weather louvres 4.3.5-3 Technical specifications 4.3.5-4 Control and monitoring systems. 4.3.5 -4.1 Charging air temperature control 4.3.5 - 4.2 Monitoring system 4.3.5-5 Commissioning and maintenance 4.3.5 - 5.1 Commissioning _ 4.3.5 - 5.2 Maintenance 4.3.5-6 Possible system malfunctions and corrective measures 4.3.5-7 Drawings: Intake air schematic MBD- D11.83031-0017 4.3.5-8 Description of accessories - see Plant Accessories appendix POWER BARGE Issued: 17.02.2000 Revision: Page 1 of 15 ESPERANZA Dr. SanticMAN Intake Air System © 4.3.5 4.3.5-1- SAFETY REGULATIONS Symbols and their meanings The symbols DANGER!, WARNING! and ATTENTION! are to be found in various sections of this description. DANGER! These symbols must be respected in order to prevent injury to yourself or other people. These symbols must be respected in order to prevent destruction of equipment or loss of functionality of the system. ATTENTION! These symbols must be respected in order to ensure the effectiveness and condition of the plant in operation. Other alerting signs: IMPORTANT ! The responsibilities and tasks of all personnel involved in the operation and maintenance of the plant must include a full understanding of the procedures in case of DANGER, ATTENTION, or NOTE, to reduce or eliminate hazards. See also the Safety Data Sheet. General: e The plant must only be used for the intended purpose for which it has been constructed, and which is given in the technical specifications. Any other use beyond that shall be considered not a proper use. The manufacturer accepts no liability for any damage resulting therefrom; any risks involved shall be borne by the operator. e The proper intended use also includes following the assembly, disassembly, commissioning, operating, and maintenance instructions issued by the manufacturer. e No alterations may be made to the system without the explicit permission of MBD and the accessory manufacturer. In particular, adding or removing parts is not permitted. e Repairs must only be made using OEM parts. Any use of components from other manufacturers which have not been explicitly approved by the equipment manufacturer is not permitted. POWER BARGE Issued: 47.02.2000 Revision: Page 2 of 15 ESPERANZA Dr. Santic(: mari\ Intake Air System Cc 4.3.5 DANGERS IF SAFETY REGULATIONS ARE NOT OBSERVED Not observing the safety instructions can mean danger to people, the environment, or the system. Not observing the safety instructions can also lead to the loss of any guarantees on system components. Specifically, not observing the safety instructions can result in the following risks, for example: e Failure of the system’s most important functions - Failure of the essential maintenance methods and of lay-up protection e Danger to life and limb from the electrical or mechanical effects Safety Data Sheet e With respect to safety, the operating company must establish clear areas of responsibility and binding guidelines, so that responsibilities for the commissioning, operation, and maintenance of the system are clearly specified and can be observed. e The operating company must ensure cleanliness and tidiness by appropriate instructions and checks. e Operating points of monitoring and control instruments, such as pressure switches, thermo- stats, valves etc., which have been set by MBD or the component manufacturer, must not be altered. e The system must only be operated, serviced, and repaired by personnel trained and instructed for this. e Actions which impair the safety of the system are not permitted. e Any internal fouling, such as paint or material that has come loose, endangers the engine. The filters and accessories of the system must be resistant to abrasion and suction. Additional safety notes: e All parts of the intake air system (bolts, lock washers, etc.) must be secured so that they cannot come loose and be sucked into the turbocharger under any circumstances. © The intake air system between the air filter and the engine must be air-tight, otherwise uncleaned air will get into the engine. e The used cleaning oil and the filter residues from the oil-bath circulating filter must be disposed of according to regulations. e The pressure drop from the filter under extreme dust loads should not exceed 0.8 mbar. e The oil tank of the oil-bath circulating filter must not be over-filled. e The filter panels should always be in a horizontal position, and the drive chain be tensioned correctly. e When decoupling electric motors of the filter drive, make sure that the filter panels cannot rotate unintentionally. See also the safety instructions in the Engine Descriptions and the descriptions in the Plant Accessories appendix. POWER BARGE Issued: 17.02.2000 Revision: Page 3 of 15 ESPERANZA Dr. Santic(mas Intake Air System Cc 4.3.5 4.3.5-2 SYSTEM DESCRIPTION 4.3.5-2.1 Overview For complete combustion of the fuel in the engine, a certain quantity of fresh air is needed, which must be supplied to the diesel engine from outdoors via a suction air line. The state of the intake air (relative humidity, air pressure and temperature, dust content, etc.) affects the output, service life, and maintenance costs of the engine facility; therefore, the air must be filtered at the engine intake. The intake air system between the air filter and the engine must be air-tight, otherwise uncleaned air will get into the engine. On the Power Barge, seven intake air systems (one for each engine) are installed. The intake air system is shown in MBD schematic diagram No. D11.83031-0017. In addition to this description, please also read the Engine Descriptions C 2.1.1 (Section 2.4.1: Fresh Air /Charging Air /Exhaust System) and the functional description in Section A 4.13: CHATCO - Charging Air Temperature Control. The intake air system consists of: 1. Weather hood Moisture eliminator Louvres Oil-bath circulating filter Transition piece to absorption muffler Absorption muffler (two mufflers in sequence) Transition Y-piece with two connections to pipeline Pipeline to the turbochargers (two pipes) Rubber expansion fittings CONDI P WN The moisture eliminator prevents water getting into the filter's oil pan; the louvres prevent birds, rain, ice or tree leaves getting into the intake air system; the oil-bath circulating filter cleans dirt particles from the intake air; the intake air mufflers muffle the noise generated by the compressor; the rubber expansion fittings between the engine's turbocharger and the intake air system isolate the engine from the system with respect to structure-borne noise and thermal expansion. The engine requires 132,900 to 136,100 kg/h of air for combustion and flushing out the combustion chamber. 4.3.5-2.2 Negative static pressure (suction pressure) A negative static pressure (corresponding to the resistance in the intake air system), which reaches its greatest value at the engine’s charging-air inlet, is created at the suction side of the compressor. This must not exceed 2,000 Pa (20 mbar). Normally, this value can hardly be reached in the intake air system if the filters are cleaned properly. If the total pressure drop is exceeded, increased fuel consumption and EON changes in the make-up of the exhaust gas will result. POWER BARGE Issued: 17.02.2000 Revision: Page 4 of 15 ESPERANZA Dr. Santiconues Iq VZNVYsdSS GLjogebeq = :uols|Aay 0002'Z0'2| :panss| d9uvd YaMOd WVHOVIG HIV SYVLNI SN19SN3 SNIUYOLINON SNTROLINOA 3oa1d_NOILondsu (ad WA OI 070 oan SsoNveuzean aaa SIV _3¥VINT Lananvsny agas3qvo3 (£001L4 NI. “TONI VbbOulV yoqu o°@=d0 yoqu o-g=dv xow $03°804 vos] [vz0o1a (¥)aP os) sey 0 wieyshs any eye.u MSEI sks Aly eye IU] NUNMAN Intake Air System © 4.3.5 4.3.5 - 2.3 Oil-bath circulating filter The function of the oil-bath circulating filter is to clean the intake air of particles of dirt. It functions automatically, supplying the diesel engine with cleaned intake air. The oil-bath circulating filter works on the principle of continuous moist filtering: the airborne particles in the incoming flow of air stick to the adhesive, oil-wetted thick mats (filter elements). The filter elements are fastened into compartments or cells, which are guided by roller chains on both sides. An oil pan with adhesive oil is located in the lower part of the filter. The filter elements move vertically upwards on the chain system across the front of the filter, forming a continuous curtain through which the cleaned intake air flows. At the rear of the filter, the dirt particles are rinsed off the filter cells when the latter reverse direction in the oil bath. The movements of the filter are controlled by a cycle timer. The filter cells move upwards about 50 mm over a period of 5 minutes, followed by 30 minutes’ standstill. During the standstill period, the excess wetting oil drips out of the filter cells. A clearing device for removing the filter sludge from the oil pan is provided. 4.3.5 - 2.3.1. Main components of the oil-bath circulating filter — Clearing device for removing the filter sludge — Inspection door and oil gauge glass — Differential-pressure switch and pressure gauge — Oil gauge glass — Manual drive adjustment — Control cubicle POWER BARGE Issued: 17.02.2000 Revision: Page 6 of 15 ESPERANZA Dr. Santiconues Jd VZNVYAdSS G1 JoLeBed — :uos|noy 0002’Z0' 21 :panss| uve YaMOd YALA ONILVINOYID HLVE NO WAS SS3Nx9 sINVH ANG usv4os a5aN1s | + woe II || | HE a a SONVALLIV py SECRET neyo F 67 Tthaate ee nv o,| Hf “5anis| Wa 008 Zeer SzvMOLNY 00H waHivan| pared OF Assy i = NIV I Te asey x | 1081n0} [eal az'szsz worniy nowis lam wiz ‘aon aAnot 6 ete Lor i ous) Sifs-ai X NOMBIA X_LHOISNY sep 9 wie}shs aly eye}uy NVINae Intake Air System ce 4.3.5 4.3.5 - 2.4 Intake air muffler Due to the flow of air at higher speed, and to resonance phenomena in the piping, oscillations of the gas column occur in the intake air system, which are superimposed on the stationary current as pressure and speed fluctuations. The intake air muffler muffles mainly the noise of the compressor. These flow noises are muffled in two intake air absorption mufflers connected in series. A silicone bellows is provided between the mufflers to isolate the two mufflers from one another with respect to structure-borne noise. The intake air mufflers, as well as the entire intake air system, have a 120-mm thick layer of acoustical insulation. Structure The air flows through numerous silencers connected in parallel. These consist of rockwool surrounded by a silk fleece, covered by perforated sheet metal and installed in a U-shaped peripheral frame of galvanized sheet steel. The muffler is provided with a protective grating (mesh width ca. 10 mm) on both sides, as protection against fouling by larger objects. 4.3.5 -2.5 Fixed weather louvres (with bird screen and frame) Due to the Z-shaped slats of the fixed weather louvres, rain, leaves, or birds cannot get into the filter, while the air can flow freely between the slats. The fixed weather louvres have a rectangular shape, and are matched to the filter size, with a frame and a flange connection. POWER BARGE Issued: 17.02.2000 Revision: Page 8 of 15 ESPERANZA Dr. SanticMAN Intake Air System Cc 4.3.5 4.3.5-3 TECHNICAL SPECIFICATIONS Accessory No: | Designation =~ ‘Technical specifications AIRO11 (1-7) | Louvres FILOO7 (1-7) | Intake air filter Oil-bath circulating filter, model 13-87 600 EM 230 V. 60 Hz 3x0.1 kW $SL001 (1-7) | Intake air mufflers 50 dB(A) (absorption mufflers) POWER BARGE Issued: 17.02.2000 Revision: Page 9 of 15 ESPERANZA Dr. Santiccars \ Intake Air System eC 4.3.5 4.3.5-4 CONTROL AND MONITORING SYSTEMS 4.3.5 -4.1 Charging air temperature control Regulating the charging-air temperature according to the ambient temperature (CHATCO: CHarge Air Temperature Control) is necessary in order to prevent condensate precipitating in the charging-air line. This closed-loop control is described in detail in Section A 4.1.3 A 4.13 - CHATCO (Charge Air Temperature Control). The response of the control system is determined by a parametrizable characteristic in the controller. While the engine is running, two modes of operation are distinguished: e Preheating mode, which is independent of the ambient temperature (two different versions). e Temperature control as a function of the ambient temperature. The condition for switching between preheat and temperature-control modes is defined as follows: Preheat mode : This is activated by the controls if: — the output is less than the output limit value for preheating the charging air. Temperature-control mode : This is enabled by the controls if: — the output is greater than the output limit value for preheating the charging air. (For the adjustment parameters for output limits, see Section A 4.13 - CHATCO Charge Air Temperature Control). Preheating the charging air by closing the L.T. section Preheating the charging air is done by closing the L.T. section (cooler section) of the intercooler. The condition for switching between preheat mode and temperature-control mode is described in detail in Section A 4.1.3. POWER BARGE Issued: 17.02.2000 Revision: Page 10 of 15 ESPERANZA Dr. Santic(an \ Intake Air System C 4.3.5 Charging-air temperature control The flow of L.T. cooling water through the L.T. section of the intercooler is regulated by an external controller by means of a control valve, as a function of the ambient temperature and the charging-air temperature required for this. The characteristic curve for the charging-air temperature setpoint shown below is stored in the controller itself: Charge-air temperature 1 Charge-air temperature setpoint characteristic Charge-air temperature ----! setpoint SW2 Charge-air temperature setpoint SW1 Ambient air temperature i i i i r 1 1 1 Hl 1 \ Hl 1 1 1 i H ‘Ambient air temperature ‘Ambient air temperature limit value TG1 limit value TG2 Then the charging-air temperature t2 is measured, and the flow of cooling water through the L.T. section of the intercooler is regulated until the setpoint and actual value of the charging-air temperature coincide. The following table shows the settings that must not be exceeded: Parameters, charging-air temperature control Settings *) Lower limit, ambient temperature TG1 25°C Upper limit, ambient temperature TG2 38°C Lower limit, charging-air temperature setpoint SW1 47°C Upper limit, charging-air temperature setpoint SW2 58°C *) Note: The final settings will be determined after commissioning 4.3.5-4.2 Monitoring system An extensive monitoring system for the charging-air system is provided. The intake air system contains numerous local indicating instruments and a remote monitoring system — see also the LIST OF MEASURING AND CONTROL DEVICES S11.99400-0651, Charge Air, Sheet 38-40, and the Engine Description C 2.1.1-2.4.1. POWER BARGE Issued: 17.02.2000 Revision: Page 11 of 15 ESPERANZA Dr. Santicman Intake Air System C 4.3.5 In addition, the operator can invoke a separate diagram for each of Engines 1 to 7 on the display screen of the COROS system, and see ihe: e pressure difference of the oil-bath circulating filter e — charging-air pressure after the intercooler e — charging-air temperature ahead of the engine If a specific value of the intake-air pressure difference is reached (4 mbar), an alarm is triggered. Then the cause of the alarm must be determined and corrected (for further details, see 4.3.5-8 ,Operating Description for Autoflo Air Filter 600 EM", in the Plant Accessories appendix). If a specific value of the charging-air temperature ahead of the cylinder is reached (62°C), an alarm is triggered. This alarm is suppressed while the engine is warming up. In case of excessive charging-air temperature or a failure of the monitoring system, a group alarm is triggered in the EMCS (Engine Monitoring and Control System). A number of the pressure and temperature values are monitored in the EDS system (CoCos), in order to perform system diagnosis and keep operating logs. Note: See also Sections 3.3.5 Monitoring System - EDS (CoCoS)- Engine Diagnosis System and A 4.13 - CHATCO Charge Air Temperature Control POWER BARGE Issued: 17.02.2000 Revision: Page 12 of 15 ESPERANZA Dr. SanticMAN Intake Air System eC 4.3.5 4.3.5-5 COMMISSIONING AND MAINTENANCE 4.3.5 -5.1 Commissioning Before being put into service, the oil-bath circulating filter must run for at least 24 hours, in order to ensure that the filters are wetted with oil. The oil-bath circulating filter should run continuously, and only be switched off when necessary for maintenance work. Regarding the commissioning of the oil-bath circulating filter, please read 670 C "Installation, Operation and Maintenance Instructions for AUTOFLO 600 EW” in the Plant Accessories appendix. For filtering the intake air, an adhesive oil is needed. This oil is located in a tank in the lower part of the oil-bath circulating filter. The tank is supposed to be filled with about 535 litres of oil. Recommended wetting oils: Ambient temperature -10°C to +6°C Shell Tellus R 10 -5°C to +16°C Shell Tellus V 15 +6°C to +27°C Shell Tellus R 22 +16°C to +38°C Shell Tellus R 37 +28°C to +52°C Shell Tellus R 100 POWER BARGE Issued: 17.02.2000 Revision: Page 13 of 15 ESPERANZA Dr. Santicae Intake Air System Cc 4.3.5 4.3.5-5.2 Maintenance The oil-bath circulating filter is designed for continuous operation under difficult conditions. The adhesive oil in the filter oil bath usually does not need to be replaced. Maintenance requirements of the filter have been reduced to a minimum. These consist of the inspection and maintenance of the mechanical parts of the paternoster system (drive elements, conveyor chains, chainwheels, bearings, guides, etc.), regular removal of the sludge from the oil tank, topping up the amount of oil consumed, and cleaning filter panels. Regarding the maintenance of the oil-bath circulating filter, please read 670 C "Installation, Operation and Maintenance Instructions for AUTOFLO 600 EM” in the Plant Accessories appendix. When topping up the wetting oil in the oil-bath circulating filter, be careful not to overfill the tank. In order to prevent overfilling, an overflow pipe must be installed at the "Overflow Opening” provided. And a drain pipe with valve (see sketch below) must also be installed at the "Drain Opening” for draining the oil tank. Recommended drainage and overflow pipes at the rear of the filter POWER BARGE Issued: 17.02.2000 Revision: Page 14 of 15 ESPERANZA Dr. SanticMAN Intake Air System Cc 4.3.5 4.3.5-6 POSSIBLE SYSTEM MALFUNCTIONS AND CORRECTIVE MEASURES (TROUBLE SHOOTING) Regarding possible system malfunctions and corrective measures, please read "Installation, Operation and Maintenance Instructions for AUTOFLO 600 EM" in the Plant Accessories appendix, and the Engine Descriptions. 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SEE DRKC NO. 8 SEF BBBa Sas ST Boia oe | owner CON Kvaerner Masa Marine vance BARGE DESIGNER | TRACTOR ER. CANADA ANNAPOLIS, U.S.A PORTLAND. 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GERMANY | ‘)) gy & if gs 1 + 2a) ' > . ik & i | |g it 4 Kvaerner Masa Marine ir) i 4 i a VANCOUVER, CANADA —_—_AWNABCLIS, U.S.A | . | : i | | #4 CASCADE GENERAL|| | f | i | | Ce roercm0 sare r] | | { 1 | | s PORTLAND, OREGON 5 | ' | 8 i tt | 2| SIEMENS | 1 | Bl doe rtey ates | it | & | Seine she | . it | eucen cron | * | - | | it g 3 | | | | { r | 5 | 1 it H | ‘ | it F12 344 , . +—+4 | J g | { 1 H : 4 a + j f | ; “aS SSS ; : t i I] | a a q 4 a A 300 +3600 ar g | 1 JANSAUGLUFT-SYSTEM ON 1109)" | i 40.00 B11. 67000-0161 — |eAd| vital it metMAN Intake air system C 4.3.5 Accessories Annexe Designation Ident No. 670A _| Oil bath circulation filter LOCKER AIR-MAZE AUTOFLO600EM installation, operation and maintenance instructions AUTOFLO EM IOM 670B_ |Absorption silencer WILLICH&GERBER Drawing SE99-052 7_Intake air system Power Barge Issued: 22.02.00 Revision: Page 1/1 Esperanza Simon TKUTHE CLEAR CHOICE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS FOR AUTOFLO 600 EM Doc. AUTOFLO EM IOM Rev. 01 Date 24 March, 1999 Locker Filtration LimitedINDEX SECTION CONTENTS AUTOFLO 600 FILTER 1.1 Recommended Adhesive Oils 1.2 Oil Tank Capacities ASSEMBLY & INSTALLATION INSTRUCTIONS 2.1 General Information 2.2 Stages of Erection MAINTENANCE INSTRUCTIONS 3.1 Maintenance 3.2 Checking Drive Chain Tension 3.3 Jammed Panels 3.4 Oil Level 3.5 Major Overhaul SERVICING INSTRUCTIONS 4.1 Servicing of Filter Tank 4.2 Servicing of Filter Panel FILTER PANEL ASSEMBLY AND PARTS LIST ARRANGEMENT OF UPPER SPROCKET UPPER SPROCKET ASSEMBLY PARTS LIST MAIN DRIVE ASSEMBLY DIAGRAM MAIN DRIVE ASSEMBLY PARTS LIST WIRING DIAGRAM ADDITIONAL ACCESSORIES WIRING DIAGRAM PRESSURE SWITCH FRONT COVER PLATE ASSEMBLY PAGE 10 11 12 13 14 15 16 17SECTION 1 AUTOFLO 600 FILTER 1.1. Recommended Adhesive Oils Ambient Temperature Oil Grade -10 deg. C To +6deg.C Shell Tellus R 10 - 5 deg. C To +16 deg.C Shell Tellus V 15 +6 deg. C To +27 deg.C Shell Tellus R 22 +16 deg.C To +38 deg.C Shell Tellus R 37 +28 deg.C to +52 Ddeg.C Shell Tellus R100 1.2 Oil Tank Capacities Width No. 3 (3°0”/ 930 mm) = 125 litres Width No. 4 (4°0”/ 1240 mm) = 165 litres Width No. 5 (5’0”/ 1540 mm) = 205 litres (Larger units are multiples of the above)SECTION 2 ASSEMBLY AND INSTALLATION INSTRUCTIONS 2.1 2.2 General Information This information is intended to give the erector concise instructions for the proper installation and commissioning of Autoflo Air Filters. The instructions indicate, by stages, the checks to be made in the course of assembly. Before proceeding with the erections, the installation General Arrangement drawing and the product brochures should be studied carefully. Stages Of Erection a) b) a a e) Each Autoflo casing or section must rest on a prepared level foundation, so that when the individual units are placed in position, they may be secured together and fixed to the base without any distortion. This is extremely important. Any variation in the level of foundations must be rectified before the units are bolted together. Distortion in the casings may cause jamming of filter panels in the guide channels. On no account must the individual units be forced together on assembly. When Autoflo casings have been placed in their final positions and bolted together front and back, the assembled sections may be secured to the foundations. The Autoflo casings are now ready for final assembly. Ensure that all loose items have been removed from the Autoflo casing. Check that panels have not jammed during transit by rotating the panels in the upward direction ONLY. N.B The pawl latch on the lower drive sprocket will prevent the panels from being rotated in the reverse direction refer to Main Drive Assembly diagram on page 13. Connect electrical supply. Before switching the control panel switch “on” remove two of filter panels as per para 4.2 at the bottom of the unit to expose the main drive assembly. Ensure the actuator arm assembly clevis is correctly positioned on the sprocket and has not become dislodged during shipment. Switch the control panel to the “on” position and press the test push button and observe that the motor shaft is rotating in the correct direction as indicated and the actuator arm moves freely over the sprocket. Switch “off” and replace panels. Fill tanks with adhesive oil to the indicated level only. DO NOT OVERFILLBefore starting equipment, allow filter to run for at least 24 hours to ensure panels are oil coated. NB. The filter panel curtain time has been pre-set to operate the drive motor once every 30 minutes for a period of 4-5 minutes to move the filter panel curtain approx. 50mm - each cycle.SECTION 3 MAINTENANCE INSTRUCTIONS 3.1 3.2 Maintenance The Autoflo filter is designed for continuous operation under the most arduous conditions, and the need for routine maintenance has been reduced to an absolute minimum. The following mechanical checks, however, should be made on a scheduled basis. By doing so , major “downtime” may be eliminated. Checking Drive Chain Tension Check that the securing bolts on the left and right hand tensioning plates are tight, and that correct tension is maintained in the panel chains. Care should be taken not to over-tighten. The panels should remain horizontal in operation. Loose tensioning plates will allow the chain to “trip a tooth” on the drive sprocket. The effect would be apparent by tilting and possible jamming of panels in the guides. This fault may be rectified by the following procedure: a) Remove access plates at lower left and right front guides and remove ‘E’ clips. b) Remove one or two filter panels, giving access to the motor drive chain. c) Slacken the locking and tensioning screws on the tensioning plates. d) _Re-adjust chain, meshing in correct sprocket teeth to give horizontal panel positioning. e) Re-adjust tension and securely lock tensioning plates, observing the following procedure: The left and right hand chains should be fitted to the top and bottom sprockets and equally tensioned so that the panel attachment link located midway between the top and bottom sprocket just touches the inner face of the panel guide channel (see sketch) f) Replace panels and secure with ‘E’ clips. g) Replace access plates and secure with bolts.AUTOFLO AIR FILTER 600 SERIES Leaf Spring Inside Face of Channel Guide Panel Attachment Direction of curtain movement Link Direction of Airflow SrEEEEHPEEE EERE Checking drive chain tension (item 3.2 (E)Note: 3.3 3.4 3.5 Jammed Panels Should the panels become jammed, do not attempt to release by forcing the curtain. The probable cause will be broken leaf springs which are located inside the front left and right hand of the casing, close to the top sprockets. a) Remove top front sheet metal cover plate. b) Remove access plates. c) Remove one or two filter panels to remove motor drive chain. this will allow movement of the filter panel curtain to unjam the affected panel and enable the panel curtain to be operated normally. d) CHECK LEAF SPRINGS. If springs are broken, it will be necessary to rotate the panels until access is gained to the leaf spring retaining rivets. e) Fit new leaf springs and re-assemble. Care must be taken to ensure that the panel assembly cannot rotate inadvertently while the motor drive is disconnected. Oil level The oil should be maintained to the level indicated by the plate inside the oil tank. The oil level should be checked periodically and topped up as necessary, using only an approved oil adhesive. The solid collected by the filter will be deposited in the tank and form a sludge which will tend to settle in the base of the tank. _-a) Remove sludge with scraper provided. b) Top up with clean adhesive oil to the indicated level. Major Overhaul Major overhaul periods will be determined by the atmospheric conditions encountered at the installation, but will not normally be required more frequently than every three years. The overhaul will consist of a complete dismantling of the filter assembly, including panel chain and sprocket assemblies. A check should be made on the following components and assemblies for possible wear or malfunction. a) Top sprocket assemblies, including bearings. Check for wear. b) Panel drive chains and panel mounting lugs. Check that all lugs are securely riveted into the main links.Note e) Main drive shaft. Remove pins from panel drive sprockets. Remove nuts holding sprocket plates to side plate. Dismantle shaft from Autoflo removing sprocket assemblies in the process. Bottom sprocket assemblies. Check for possible wear. Bearing bushes. These should be checked for wear and replaced if necessary. When re-assembling, the tensioning plates positioned at the top of the unit should be adjusted with the drive shaft, sprockets and chains fitted, to ensure correct tension in the panel chains. Do not over- tension. Ensure that the tensioning plates are securely locked before re- inserting the panels. ) 8) h) D i) Electric motor drive assembly. All units are fitted with pre-packed shielded ball bearings with an estimated life of 5,000 working hours, which may vary depending on operating conditions and temperature. We recommend replacing a noisy bearing, as re-greasing will not obviate this fault. Desludge. Thoroughly clean the oil tank. Clean panels. If cleaning of panels is necessary, this should be carried out by soaking in kerosene or other suitable cleaning fluid. Blow out from the clean side of the media with compressed air. Check for clearance of solids from the media labyrinth by holding the panel up to the light. Clogged dirt will be denoted by areas of ‘blanking’ in the media. These should be cleared. Check panels for damage to frame or media. Damaged units should be renewed. Ensure correct rotation of filter curtain after re-assembly. Refill tank with clean oil adhesive. As specified by the filter manufacturer. Care should be taken not to overfill the tanks.SECTION 4 SERVICING INSTRUCTIONS 4] Servicing of Filter Tank a) b) °) 4.2 a) b) °) 4) 8) h) The sludge which is deposited in the oil tank must be removed at regular intervals. The frequency of removal will depend upon local environmental pollutants. The sludge should not be allowed to accumulate to a depth of more than 70 mm. When the filter is first installed, the tank should be inspected every two weeks to determine the rate at which sludge is being deposited. Some oil will be lost with the sludge, and must be replaced with fresh oil. The oil should be maintained at the oil level mark 7 Contamination of oil. Checks to be made at regular intervals. The only test possible is a visual check to see if the oil has emulsified. If emulsified the oil will have become cloudy and discoloured with resinous particles in suspension. A complete oil change should be made to ensure efficient working of filter. Servicing of Filter Panel If it becomes necessary to remove any or all of the filter panels, for any reasons, the procedure below should be followed. Place the control box door switch in the ‘off position. Unbolt the two access plates on the front of the Autoflo guide channels. These plates are located 1m up from bottom of the filter. Remove the 2 wire E clips from the panel support pins with long nosed pliers. Slip the panel support pins from the conveyor chain lugs, freeing the panel. Remove the panel. Release lower drive shaft motor drive to allow manual movement of the filter panel curtain. Move the filter curtain up again by hand until the next panel in framed in the opening. Remove all panels in this manner. To replace the panels in the filter housing, reverse the process, being sure to replace the wire E clips on the panel support pins. Spare E clips are provided with each Autoflo assembly. Replace motor drive chain.FILTER PANEL ASSEMBLY AND PARTS LIST ITEM NO DESCRIPTION REF NO NO OFF 1 Access Plate D3323 2 2 M6 Hex Nut 1925003 4 3 6 mm Dia Flat Washer 1925002 4 4 Panel B 3350 - 5 ‘E’ Clip * 1913004 2 Per Panel Panel Assembly typical both sides of caseARRANGEMENT OF UPPER SPROCKET NOTE ITEM 5 MUST BE FREE RUNNING AUTOFLO END PLATE»UPPER SPROCKET ASSEMBLY PARTS LIST ITEM DESCRIPTION TYPE QTY Clamping Plate D4471 M6 x 1C’SK Head Set Screw 12 mm long | B2010/9 Plate & Stub Shaft Assy €20102 Roller Bearing B20101/4 Sprocket C4472 M10 Hez Nut 1925007 M10 Flat Washer 1926004 M12 Hex Nut 1925009 M12 Hex Hd Set Screw 95mm long 1924120 11MAIN DRIVE ASSEMBLY DIAGRAM (For Parts List see over) Ratchet to prevent 8 - 7, | panels being rotated in reverse directionMAIN DRIVE ASSEMBLY - PARTS IDENTIFICATION LIST Item No. Description Type Qty 1 Mounting Plate 20095 2 z Lower Sprocket Bearing (inner) | D24971 2 e) Lower Sprocket C20216 2 4 MS x 10 Grubscrew 26606/10 3 5 Roll Pin B20212/5 2 6 Lower Drive Shaft D26290 1 7 Sprocket Assembly 26606/4 1 8 Motor Drive Bracket C26662 1 9 Motor SD13 WS (TEFC) 3033001 1 10 Motor Drive-Wheel 26606/3 1 ll Actuator Arm Assembly 26606/1 1 12. M6 Washer 1926002 4 13 M6 Hex Nut Nyloc 1925030 4 13SECTION 5 ADDITIONAL ACCESSORIES 5.1 Mosquito Screen Fitted To Autoflo The screen is attached to Autoflo by 4 screws, for desludging of tank remove 2 screws at bottom of screen and loosen only 2 screws at top of screen. Swing screen out to allow tank top to be lifted. Clean tank in accordance with servicing instructions Section 4.1. Refit screen tightening 2 top screws and replacing 2 bottom screws.FRONT COVER PLATE ASSEMBLY ITEM DESCRIPTION REF NO.OFF I, Cover Plate C12978 1 2. Leaf Spring D3238 2 3. M3 Cheese Head Screw 1927019 4 4. M3 Flat Washer 1926033 8 5 M3 Nyloc Nut 1925 4 17tslos|ss|psiesizsl is elev ensy, ev ale ke] Ita} Fa) Wel panel. i (a33D)a3sq1> ATTaWAOU: HILIMS Banssayd ayo 320/00 ol 33d Hs O44 1 tar Nou | on Wy bisaPressure ia switcH ‘ d THAUTOFLO CONTROL BOX DRAWING NO. B25303 Operation Description With the power supply onto the motor drive circuit a timer is set to switch power onto - the motor for 5 minutes and then off for 30 minutes. This is so that the filter panels travel a distance of 50 mm approximately during 5 minutes and then remains stationary for 30 minutes allowing time for any excess oil to drain from the filter panel mesh media back down into the adhesive oil sump. A red light on the outside of the control panel indicates that the power supply is on. Agreen light on the outside of the control panel indicates that the power is being applied to the electric drive motor. R2 provides a volt free contact normally open to indicate that power is being applied to the electric drive motor. A CMR pressure sensor 196-115 provides a 4 - 20 mAmp (0-100mmWG) signal for remote indication of the differential pressure (D.P.) across the filter. 2 Dwyer D.P switches are provided in the control box to give alarm and shutdown signals. The alarm pressure switch is normally closed and local green light indicates that the pressure drop is acceptable. When the D.P. rises above the desired level normally 25 mmW4g a local lamp indicates alarm D.P. A volt free contact via R1 gives remote indication of alarm D.P. When alarm indication is received an inspection of the filter should be made to discover the cause of the high D.P. The shutdown D.P. switch is set to 35 mmWg give a remote indication. On this signal being received the engine should be shutdown and the filter should be inspected to discover the cause of the high D.P.AUTOFLO CONTROL BOX DRAWING No. B25303 INSTALLATION POWER SUPPLY Ensure that your supply voltage and earthing connections to the contro! box are in accordance with the relevant Regulations or Codes of Practice of your local or supply Authority. Ensure also that your voltage and frequency agrees with the voltage and frequency as indicated on the drawing B25303. After connecting power supply ensure that the correct rotation of the filter panels with in the housing assembly. An independent 24 supply has to be connected into the pressure sensing circuit. A4-20 mAmp signal and Volt Free contacts require connection to a remote station.~ MAINS ASOLATOR ON oFF| 7 x “1 DANGER, 240V AC POWER O° Motor, RUNNIN S| bO i PRESORE NORMAL, O PRESSURE HIGH OQ, Cpe (1) (19) Ol® ® & [PARTS LIST FOR CONTROL BOX B25303 ITEM PART NUMBER, QTY DESCRIPTION FR OEM SENSOR ( CMR PART # 196-115 ) ERE PRESSURE SWITCH DWYER MODEL 1910-1 FRE MAGNEHELIC D. P. GAUGE DWYER 2000 0-50 WG. EERE 8 PIN PLUG IN RELAY BASE R'S. REF. 401-009 corr 8 PIN D.P.C.O. RELAY R.S. REF. 348-762 RE 8 PIN D.P.C.O. RELAY R.S. REF. 348-784 FREE TIMER BASE OMRON-P2CF-08 FR TIMER OMRON-H3CR-F8 FR FUSE NON INDICATOR KLIPON TYPE 3.15 PT.# 043110 S| OP} 29} Q] a} ] A} LD] wo] ERE RED LIGHT ZB2-BV7 & ZB2-BV04 7 ee GREEN LIGHT ZB2-BV7 & ZB2-BV03 5 PRK BULB BAS R.S. 589-468 MIN. QTY 10 G EE PUSH BUTTON ZB2-BD2 & ZB2-BA2 a PERE hela) tofr} ele} alot ofol elo} a ISOLATOR