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Filtek filtration system - Installation manual for generators-v2

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  • Installation Manual: Filtek Filtration Systems

    IntroductionGeneralDue to the varying design of diesel generators (DG) themselves and the associated sound proof canopy no two installations may ever be 100% identical. As such this manual is designed to act as a comprehensive guide to ensure correct installation and connections of all Filtek components.

    Should the variances of your particular DG not be present in this manual the same principles illustrated must be applied.

    The OEM Oil and fuel filters are complimented by Filtek and not replaced by Filtek.

    The table below should be followed in sequence

    Table of Contents1. Verify installation kit components2. Indentifying a mounting location3. Determining the height of a base mounting plate4. Oil Canister installation and connections5. Fuel Canister installation and connections6. FAD installation and connections7. Testing and commissioning8. Trouble shooting the system & FAQs

    Superior Filtration Solutions

    Page 1

  • 1) Installation Kit Components (supplied)

    Prior to commencement of any installation verify that the kit components been hoses, adaptors, clamps and connectors are present and accounted for as per below listing

    Note: for large scale deployment on a specific generator model the hoses lengths and JIC connect angles must be specified in advance. This will then be made to order.

    Kits components are supplied separately for the oil canister, fuel canister and FAD.

    1.1 Oil Canister - Kit components

    Website URL: www.filtek.coContact email: [email protected]iltek.coContact cell : +27 72 059 9363

    +27 83 451 3647

    * Illustrations show variations of the same part NOT quantities Page 1

  • 1.2 Fuel Canister - Kit components

    1.3 Auto-Oil Dispenser (FAD) - Kit components

    * Illustrations show variations of the same part NOT quantities

    * Illustrations show variations of the same part NOT quantities

    Page 3

  • 2) Indentifying a mounting location

    The best option is to take both the Oil and Fuel canisters to the generator itself. If a FAD is to be fitted then this part should also accompany the initial survey. There are no real prerequisites for the installation of both the Oil and Fuel filters , however the FAD has a very specific height requirement. If you intend to fit a FAD pls see section #3.

    Of the options listed below Filtek recommends #2.1 local manufacture of a base mounting plate and that it is manufactured to the correct height for a FAD, irrespective if one will be installed initially. This will ensure the entire base mounting plate remains future proof.

    Canister Mounting Options2.1. Option 1_Base mounting plate. This plate must be locally manufactured and is designed to fit within the generator canopy itself. The Oil canister, Fuel canister and FAD will mount onto this base plate. To avoid excessive vibration the base plate is mounted to the base (frame) of the generator and not the generator itself. A template drawing of a typical base plate can be provided upon request .

    Base mounting plate

    Below is a illustration of an alternative base mounting plate option. This option is more elaborate and expensive to manufacturer than the above and therefore not recommended.

    Page 4

  • 2) Indentifying a mounting location (cont)

    2.2. Option 2_Canopy mountShould a suitable mounting base plate not be viable the canisters can be directly mounted onto the sound proof canopy itself. This will require holes to be drilled into the canopy itself and therefore the use of large washers are recommended.

    Below is illustrations of such installations. The hose connection to the canisters are all straight.

    2.3. Option 3_Outside the canopyIn the case where the installation is required solely for trial purposes meaning the system will be decommissioned upon conclusion of the 1,000hr trial, mounting of the canisters outside may be considered. The hoses may then be fed through the vents of the canopy which will still allow the canopy to be locked. This method is of course not visually appealing and should be considered temporary in nature, for trial purposes only.

    2.4 Other mounting optionsThe services of a mechanical engineer are recommended to assist with the design of a base mounting plate. The base plate is only required to be designed once per generator model/ canopy type. A detailed database of the above should be kept for future records when installing Filtek systems on a variety of generators.

    Mounting options are finite so above only serves as conceptual ideas. Filtek recommends option #2.1 due the fact it is acceptable in appearance and allows for both canisters and FAD mounting.

    When large scale deployment takes place on a the exact same DGs the correct hose lengths and JIC connector angles must be specified upon order.

    Canister is mounted with its bracket in the vertical position. Hose connections are straight.

    Canister is mounted with its bracket in the horizontal position. Hoses connections are 90 degrees.

    Page 5

  • 3. Determining the height of a base mounting plate

    When recommended mounting option #2.1 is selected the height of the mounting base plate is determined by the principle of operation of the FAD itself.

    This measurement only has to be taken once per generator / canopy type so ensure record keeping for future deployment.

    3.1 Ensure the generator has a ball valve connected to the sump plug.3.2 Connect a 1m clear hose to the free end of the ball valve and ensure the open end of the

    clear hose is cable tied to well above the estimated oil level in the sump.3.3 Ensure the generator oil is at the correct level as specified by the OEM.3.4 Open the ball valve and allow the oil to fill the clear hose.3.5 Measure the height of the top of the oil level in the hose to the OEM base mount of the generator itself onto which the locally manufactured base mounting plate will be bolted.3.6 Write down the height and perform the simple calculation below to determine the height of the base mounting plate . This is height X.3.7 Z is the height of the FAD above the base mounting plate. Z is 55mm for plastic type and 25mm for the Aluminium type.

    X minus Z = Y base plate height

    Sumpcorrectoillevel

    Clearhose

    DGmounting DGmounting

    X Y

    Z=55or25mm

    LocallymanufacturedbasemountingplateforFiltek.Yisthebaseplateheight

    Ballvalve

    Z=25mmZ=55mm

    FAD type A - Plastic Z is 55mm

    FAD type B - AluminiumZ is 25mm

    Note : bracket between brass lock nuts

    Mount to DG base, not after engine shock mount to avoid excessive vibration.

    Page 6

  • 4.0 Oil Canister Installation and connections

    This section assumes a suitable location has been identified for the Oil canister which has now already been mounted.

    The following aspects will be covered in this section:-4.1 Connections from the Oil canister4.2 Connections to the generator

    4.2.1 High pressure output source for the generator. (Oil canister input)4.2.2 Low pressure return to the sump. (Oil canister output)

    Note: The Filtek Oil filter does NOT affect generator oil pressure due to the very small orifice on the input which prevents any such change. A simple test can confirm this. Connect a ball valve to the input of the oil canister. Run the generator for a few minutes to operational temperature with the ball valve open. Check the filter is function correctly by checking that it is hot (caution: same temperature as engine). Whilst running open and close the valve while monitoring engine pressure. A small change may be noticed upon opening but will return to normal within a few seconds once the oil canister is full again and has stabilised.

    Element gauge (element resistance)

    Input diffuser (pressure limiter)

    Pressure regulator (max 3bar)

    Output (return to generator)

    Mounting bracket

    4.1 Connections from the Oil canister

    The canister incorporates the following:-

    1. Input diffuser - contains a very small orifice so as NOT to affect engine oil pressure orvoid OEM warranty in anyway.

    2. Pressure regulator limits internal pressure to maximum of 3bar. Excess pressure willbe bypassed.

    3. Element gauge measures the resistance between the input and output. (It is not ameasure of engine pressure). As the element becomes saturated with contaminants so thepressure on the gauge will increase. High viscosity fluids will naturally present moreresistance. The gauge is effectively a visual inspection of the condition of the element.Normal operation would be in the green area. High readings will indicate the filter elementis blocked and severely restricting oil flow - no longer working effectively. Action: elementreplacement due.

    Connect part #3 Adaptor - 1/4"BSP * 1/4"JIC to the canister outputConnect part #4 Adaptor - 3/8" BSP * 1/4"JIC to the canister input

    Page 7

  • 4.2 Connections to the generator4.2.1 High pressure output source for the generator. (Oil canister input)

    In order for the oil filter to function correctly a high pressure (>2bar) output from the engine is required. This is normally achieved by adding a T-piece (part no #6) to the oil sender unit and tapping off a connection. Several other options exist such as using a sandwich adaptor or any alternate high pressure points.

    4.2.1.1 Option 1_from Oil Sender unit. Locate the oil sender unit within the generator and follow the below step for step instructions. While all sender units are not identical in shape size and location the principle will remain the same for all generator models.a) Remove the sender unit wiring and unscrew the unit from the generator blockb) Join and tighten parts # 5, 6 & 7

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