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MPCR & PCR Series
MPCR & PCR Series
Contaminant Removal
Filtration System
Ref: 02250137-774
MPCR & PCR
CONTAMINANT REMOVAL FILTRATION SYSTEM
Updated: 14 May 2003 - Rev 03
TABLE OF CONTENTS
SECTION 1 - SAFETY .................................................................................................... 3
1.1 GENERAL................................................................................................................................... 3
1.2 PERSONAL PROTECTIVE EQUIPMENT ................................................................................. 3
1.3 PRESSURE ................................................................................................................................ 3
1.4 FIRE AND EXPLOSION ............................................................................................................. 4
1.5 HOT SURFACES, SHARP EDGES AND SHARP CORNERS.................................................. 4
1.6 TOXIC AND IRRITATING SUBSTANCES................................................................................. 4
1.7 ELECTRICAL SHOCK ............................................................................................................... 5
1.8 LIFTING ...................................................................................................................................... 5
SECTION 2 - DESCRIPTION.......................................................................................... 5
2.1 INTRODUCTION......................................................................................................................... 5
2.2 DESCRIPTION OF COMPONENTS........................................................................................... 6
2.3 DESIGN RATINGS ..................................................................................................................... 6
SECTION 5 - OPERATION............................................................................................. 7
5.1 GENERAL................................................................................................................................... 7
5.2 INITIAL START-UP .................................................................................................................... 8
5.3 START-UP AND OPERATION................................................................................................... 8
SECTION 6 - MAINTENANCE........................................................................................ 8
6.1 GENERAL................................................................................................................................... 8
6.2 DAILY OPERATON .................................................................................................................... 9
6.3 FILTER ELEMENT CHANGE (MPCR MODELS) ...................................................................... 9
6.4 FILTER ELEMENT CHANGE (PCR MODELS) ......................................................................... 9
6.5 MAINTENANCE RECORD ......................................................................................................... 9
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MPCR & PCR
CONTAMINANT REMOVAL FILTRATION SYSTEM
Updated: 14 May 2003 - Rev 03
SECTION 1 - SAFETY
1.1 GENERAL
Sullair Corporation and its subsidiaries design and manufacture all of their products so they can
be operated safely. However, the responsibility for safe operation rests with those who use and
maintain these products. The following safety precautions are offered as a guide which, if
conscientiously followed, will minimize the possibility of accidents throughout the useful life of this
equipment.
WARNING - These filters should be operated only by those who have been trained
and delegated to do so, and who have read and understand this User Manual.
Failure to follow the instructions, procedures and safety precautions in this manual
can result in accidents and injuries.
DO NOT attempt to operate the filter system in a known unsafe condition. Tag the filter system
and render it inoperative by disconnecting and locking out all power at source so others who may
not know of the unsafe condition will not attempt to operate it until the condition is corrected.
Install, use and operate the filter system only in full compliance with all pertinent OSHA
regulations and all applicable Federal, State, and Local codes, standards and regulations.
DO NOT modify the filter system and/or controls in any way except with written factory approval.
While not specifically applicable to all types of filters, most of the precautionary statements
contained herein are applicable to most filters and the concepts behind these statements are
generally applicable to all filters.
1.3 PRESSURE
A. Filters meet ASME codes, inspected and stamped. MPCR units are rated 200 psig maximum
working pressure at 150°F (limited by drains & elements). PCR units are rated 200 psig
maximum working pressure at 150°F (limited by drains and elements).
B. These filters are pressure vessels that MUST be protected, when installed, by a relief device
per ASME code requirements as applied to meet state and local regulations.
C. Secure all connections by wire, chain or other suitable retaining devices to prevent tools or
hose ends from being accidentally disconnected and expelled.
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MPCR & PCR
CONTAMINANT REMOVAL FILTRATION SYSTEM
Updated: 14 May 2003 - Rev 03
D. DO NOT overpressure the filter system. Maximum pressure for the standard MPCR & PCR is
200 psig. Consult factory for high pressure applications.
E. Vent ALL internal pressure prior to opening any line, fitting, hose, valve, drain plug,
connection or other component, such as filters and line oilers.
F. Keep personnel out of line with and away from the discharge opening of hoses or tools, or
other points of compressed air discharge.
G. Use air pressures less than 30 PSIG (207kPa) for cleaning purposes, and then only with
effective chip guarding and personal protective equipment per OSHA Standard 29 CFR
1910.242(b).
H. DO NOT engage in horseplay with air hose as serious injury or death may result.
I. DO NOT operate a filter system at abnormal conditions. Consult manual for normal operating
conditions.
WARNING - Death or serious Injury can result from Inhaling compressed air without
using proper safety equipment. See OSHA standards on safety equipment.
B. These filters will not remove water vapor, oil vapor, carbon monoxide or other toxic gases.
C. These filters will remove particulate and aerosols down to 0.01 micron only.
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MPCR & PCR
CONTAMINANT REMOVAL FILTRATION SYSTEM
Updated: 14 May 2003 - Rev 03
1.8 LIFTING
A. Lift and/or handle Filter system only in full compliance with OSHA standards 29 CFR 1910
subpart N.
B. Inspect points of attachment for cracked welds and for cracked, bent, corroded or otherwise
degraded members and for loose bolts or nuts prior to lifting.
C. Make sure entire lifting, rigging and supporting structure has been inspected, is in good
conditions and has a rated capacity of at least the weight of the filter system. If you are
unsure of the weight, then weigh filter system before lifting.
D. Make sure lifting hook has a functional safety latch or equivalent, and is fully engaged and
latched on the bail or slings.
E. Use guide ropes or equivalent to prevent twisting or swinging of the filter once it has been
lifted clear of the ground.
F. Keep all personnel out from under and away from the filter system whenever it is suspended.
G. Lift filter system no higher than necessary.
H. Keep lift operator in constant attendance whenever filter system is suspended.
I. Make sure forklift truck forks are full engaged and tipped back prior to lifting or transporting
the filter system.
J. Forklift no higher than necessary to clear obstacles at floor level and transport and corner at
minimum practical speeds.
K. Make sure pallet mounted filter systems are firmly bolted or otherwise secured to the pallet
prior to attempting to forklift or transport them. NEVER attempt to forklift a filter system that is
not secured to its pallet, as uneven floors or sudden stops may cause the filter system to
tumble off, possibly causing serious injury or property damage in the process.
SECTION 2 - DESCRIPTION
2.1 INTRODUCTION
The Sullair Contaminant Removal Filtration System (MPCR/PCR) is designed primarily to
eliminate various contaminants or pollutants present in the compressed air system for the
purpose of providing clean (cleaner than atmospheric), compressed air. However, the
MPCR/PCR CANNOT REMOVE WATER VAPOR, OIL VAPOR OR OIL AEROSOLS LESS
THAN 0.01 MICRON, OR CARBON MONOXIDE OR OTHER TOXIC GASES.
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MPCR & PCR
CONTAMINANT REMOVAL FILTRATION SYSTEM
Updated: 14 May 2003 - Rev 03
SECTION 3 - SPECIFICATIONS
02250137-824 MPCR TABULATED GENERAL ARRANGEMENT
02250137-822 PCR TABULATED GENERAL ARRANGEMENT
02250143-921 MPCR/PCR WIRING SCHEMATIC
SECTION 4 INSTALLATION
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MPCR & PCR
CONTAMINANT REMOVAL FILTRATION SYSTEM
Updated: 14 May 2003 - Rev 03
SECTION 5 - OPERATION
5.1 GENERAL
Contaminated compressed air enters the first stage filter from the inside of the filter cartridge
where particles of dirt, liquid lubricant and water are filtered through direct interception, inertial
impaction or diffusion. The compressed air passes through a deep bed of graded density filter
media increasing in efficiency in the direction of flow. The larger particles are trapped by the first
layer of coarse material and the remaining particles are trapped by subsequent finer layers. Solid
particles are trapped permanently within the filter material, and therefore, replacement of the
cartridge is required when dirt and other solid particles collected causes the pressure drop to
reach 5 psid on the dp gauge.
The liquid aerosols after initially being trapped by the fibers of the filter material coalesce, form
larger droplets. These droplets are carried by the air flow to the outer support core where it
appears at random as condensation. At this point, the anti re-entrainment barrier (resistant to
attack by acidic mineral and synthetic lubricants) collects the droplets as they break free and
allows them to gravitate within its cellular structure forming a “wet band” around the bottom of the
filter element. Clean filtered air passes through the anti-re-entrainment barrier above the wet level
where the resistance to flow is less, leaving a quiet zone of no air turbulence in the bottom of the
filter vessel. Through this, the separated liquid falls without being re-entrained and is removed by
the automatic drain trap from the bottom the filter housing.
The filtered air then flows through the second stage filter operating in the same principle as the
first stage filter (air flow from inside out of the filter cartridge), where air passes first through the
inner layer of the filter element consisting of an integral prefilter material which further removes
particles of dirt and liquid lubricant. This gives protection of the layer of high efficiency filter
material which removes particles to 0.01 micron. The fine liquid aerosols are trapped by the fibers
of the element and coalesce forming larger droplets. They are pushed to the outer support of the
element and into the anti-re-entrainment barrier. The droplets gravitate within is cellular structure
to the bottom of the element forming a “wet band” which provides an air seal. The cleaner filtered
air passes through the anti-re-entrainment barrier above the “wet band” where the resistance of
flow is less, leaving a quiet zone of zero gas movement in the bottom of the housing. The
separated liquid drops off without being re-entrained and is discharged by the automatic drain.
The contaminant-free air leaving the MPCR/PCR surpasses the most stringent instrument-air
requirements.
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MPCR & PCR
CONTAMINANT REMOVAL FILTRATION SYSTEM
Updated: 14 May 2003 - Rev 03
1. Check the main electrical supply to insure correct voltage (115/1/60) is provided. Light in fuse
cover shows unit is energized unless fuse “blows”.
2. Check that supply air flow rate, temperature and pressure to the unit meets the specification
requirements.
3. Check to be sure the customer installed relief valve is functioning and proper size per state
and local regulations.
The monitoring devices will indicate the operating condition of the system. Their functions are as
follows:
• First stage differential pressure gauge indicates the pressure drop across the first stage filter.
• Second stage differential pressure gauge indicates the pressure drop across the second stage
filter.
• Pressure drop indicating lights indicate if a differential pressure of 15 PSIG (103kPa) is reached
across the first or second stage filter and a light will be activated.
First Stage Differential Pressure Gauge - The pressure drop may be 0 to 2 psig. It
increases as the coalescing first stage filter continually removes contaminant particles to
1 micron.
Second Stage Differential Pressure Gauge -The pressure drop may be 0 to 1 psig. It
increases as the coalescing second stage filter continually removes contaminant particles
to 0.01 micron.
Indicating Lights and Alarm will activate if pressure drop exceeds 15 PSIG (103kPa) on
either filter (see Section 5.2).
5. The automatic drain trap will indicate the amount of emulsion being coalesced from the
compressed air as it passes through the system.
SECTION 6 - MAINTENANCE
6.1 GENERAL
By familiarizing yourself with the filtration process and the monitoring system of the unit
(consisting of a complete set of gauges and indicating light), you can easily analyze and
determine the location of any malfunction.
The first stage coalescing filter element and the second stage coalescing filter element should be
changed when the pressure drop of either filter reaches 5 psid.
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MPCR & PCR
CONTAMINANT REMOVAL FILTRATION SYSTEM
Updated: 14 May 2003 - Rev 03
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MPCR & PCR
CONTAMINANT REMOVAL FILTRATION SYSTEM
Updated: 14 May 2003 - Rev 03
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MPCR & PCR
CONTAMINANT REMOVAL FILTRATION SYSTEM
Updated: 14 May 2003 - Rev 03
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WORLDWIDE SALES AND SERVICE
SULLAIR CORPORATION
Subsidiary of Sundstrand Corporation
3700 East Michigan Boulevard,
Michigan City, Indiana 46360 – U.S.A
Toll Free (USA only): 1-800-SULLAIR
Outside the USA: 1-(219)-879-5451
Fax: 1 (219)-874-1273
Fax Parts: (219) 874-1835
Fax Service: (219) 874-1805