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Filtek filtration system - Installation manual for generators-v2

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Installation Manual: Filtek Filtration Systems Introduction General Due 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 Contents 1. Verify installation kit components 2. Indentifying a mounting location 3. Determining the height of a base mounting plate 4. Oil Canister installation and connections 5. Fuel Canister installation and connections 6. FAD installation and connections 7. Testing and commissioning 8. Trouble shooting the system & FAQ’s Superior Filtration Solutions Page 1
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Page 1: Filtek filtration system - Installation manual for generators-v2

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 & FAQ’s

Superior Filtration Solutions

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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] cell : +27 72 059 9363

+27 83 451 3647

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

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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

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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.

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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 DG’s 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.

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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

Sump correct oil level

Clear hose

DG mounting DG mounting

XY

Z = 55 or 25mm

Locally manufactured base mounting plate for Filtek. Y is the base plate height

Ball valve

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.

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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

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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 together. These can be fitted in any combination to

ensure the sender unit does not protrude and block the canopy door etc. c) Fit the part #5 to the hole in engine block left by removing the sender unit. Note if it

does fit correctly you may to use either a BSP or NPT fitting.d) Reconnect the sender unit to the to open end of part #6 and reconnect the wiring.

Part #5 to engine block where sender was removed

Part #6 determine best angles to connect parts #5 & 7

Part #7 connection to Oil canister input (part #4)

Refit the sender unit

d) If a generator already has a T-piece then a 4 way connector is recommended.e) Below are illustrations of completed connections for the high pressure output

High pressure hose part #8 or 9

4.2.1.2 Option 2_using a sandwich adaptor. A suitable sandwich adaptor which fits between the OEM spin on filter and its housing on the engine may also be used.

4.2.1.3 Option 3 _other. Several other suitable places also exist on a per generator type . Pls consult a qualified technical staff before proceeding.

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4.2 Connections to the generator4.2.2 Low pressure return to the sump. (Oil canister ‘output’). As such no recommended point for oil return exists but is rather a case of finding the most suitable low pressure return point anywhere on the generator. In the rare case that none exist the return may be via the sump connection. However if a FAD is to be installed this causes excessive ‘plumbing’ but remains a effective solution.

Certain blanking plates and grub screws can be removed to determine if they provide a return to the sump. If not sure consult the OEM of qualified technical staff.

Below are illustration of various suitable oil return points. Grub screws are generally the best if they exist. Blanking plates may also be removed and a thread tapped into them to accommodate a adaptor similar to part # 3, 4 & 7.

Grub screw type return

Alternate Dipstick returnCertain OEM’s also provide for a dip stick connection on either side of the generator. Using the adaptor plate provided the alternate side can be used. In this case all connections must be made prior to screwing the adaptor back into place on the engine block. If not done in this sequence the adaptor may bend when the hose connector is tightened and cause an oil leak.

Blanking plate type returnTap a thread in the blanking plate to accommodate part # 3, 4 or 7

Oil return from canister

FAD connection

Oil service drain

Sump type return

When deploying the sump type return it is recommend to get a 4 way BSP adaptor and to install a small section of flexible hose from the actual sump plug. This will ensure less stress on the sump plug due to vibration.

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5. Fuel Canister and Connections.

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

The fuel installation is relatively simple and only requires that a decision be made to mount the filter before or after the fuel pump. Filtek recommends the filter be mounted before the fuel pump as this will extend the life span of the pump. The only issue is that the fuel canister must be manually filled with diesel fuel and the engine ‘primed to remove any air’ before starting. Effectively the fuel canister connections inserts between the existing fuel line which supplies the generator. The Fuel canister must be mounted after the water separator which is normally located at the bulk tank outlet.

The following aspects will be covered in this section:-5.1 Connections from the fuel canister5.2 Connections to the generator and fuel supply

5.2.1 Fuel from the bulk / day tank to the canister. (Fuel canister ‘input’)Disconnect the hose from the fuel supply to the generator and replace with hoses supplied in the installation kit. Use the hose clamps supplied to ensure a tight seal.

5.2.2 Fuel to the generator. (Fuel canister ‘output’)The hose to fuel pump should already be disconnected as it is the same hose as above. Replace with hose supplied. Use the hose clamps supplied to ensure a tight seal.

Input (from bulk or day tank)

Output (to generator)

Mounting bracket

Connect part #12 Adaptor - 1/4"BSP * 1/4"JIC to the canister outputConnect part #12 Adaptor - 1/4" BSP * 1/4"JIC to the canister input

Bulk tank with water trap

Fuel connection without Filtek

Fuel connection with Filtek. Use supplied fuel hoses and clamps

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NB: The hose from the FAD must never be higher than the FAD connection itself.

In most installations the hose from the FAD will have a slight downward curve towards the ball valve connections which is correct.

6. FAD Installation and Connections.

This section assumes a suitable location has been identified for the FAD which has now already been mounted. As mentioned the height of the FAD relative to the correct oil level in the sump is critical.

The following aspects will be covered in this section6.1 Ensuring correct FAD hose levels6.2 Connecting the ball valve system. This system will create a connection to the FAD and

provision for engine oil drain from the sump. If applicable oil return may also form part of this connection.

6.1 Ensuring correct FAD hose levelsAs illustrated on page 6. Test that the height X measured is equal (+/5%) to the dashed green line level of the FAD. Once correct you may proceed with the connections.

The FAD utilises a gravity feed system. The hose connection from the FAD to the ball valve must comply with the below.

6.2 Connecting the ball valve system. Connect the listed parts as illustrated below. Filtek recommends that the ½’ nipple part #18 and hose part #21 be used as opposed to the part #19 which is shipped with all FAD’s. If however part #19 and the supplied clear hose are used they must be fitted correctly to ensure a seal.

Nipple to FAD / black hose/ ball valvepart #18 / part #21 / part#18

Connect to engine sump. If the sump already has a ball valve it should remain. Filtek recommends a short flexible hose to avoid excessive vibration. Part #16

Ball valve part #17

Nipple part # 18

Hose part #21Oil drain for maintenance. Extend outside of canopy. Insert a bolt and hose clamp to avoid leaks

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Drain ball valve is ‘normally CLOSED’ and is only opened when conducting scheduled maintenance to drain the oil. Note the hose is plugged with a bolt and hose clamp to ensure no leakages.

6.2 Connecting the ball valve system (cont).Upon connection of the ball valve system the installation should resemble the illustration below.

Note the system is cable tied to the generator chassis and NOT directly connected to the sump.

Connect to the FAD using either clear or black mining hose. Under Normal operation this ball valve is OPEN. If the generator has a OEM ball valve this may remain and must also be OPEN. Ensure this valve is closed when conducting scheduled maintenance to drain the oil.

FAD valve ‘normally OPEN’ (OEM valve ‘OPEN’)

oil drain (extend outside canopy).

Installation staff verifying the FAD height.

In this case the base mounting plate was too low and the supplied FAD bracket used to increase the FAD height

FAD been filled. Note the silver lid does NOT screw off. The FAD plunger must be hand tightened only.

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7. Testing and commissioning

Prior to switching on the generator ensure the following checks:-

7.1 Check all the JIC (37° flare)  hose connections are tightened as recommended.This connection is widely used in hydraulic systems. When the straight threads are engaged, the 37° male seat seals on the 37° female flare seat. A 37° fitting body will accept both inch and metric tube by changing the sleeve. The 37° adaptor body and nut are available with inch and metric hex, as well as a variety of port end configurations.

Flats From Finger Tight (F.F.F.T.) is a Turns Method that counts the number of hex flats past the finger tightened position =2 turns

Thread Size Nom. Size (in) # of Thrds per Inch Male Thread outer diameter (in)

Assembly Torque (in-lb)

Assembly Torque (ft-lb)

Tube Connection

FFFT

4 1/4 20 7/16 130 ‐ 150 11‐13 2

7.2 Neaten the installation. Any excess hose may be rolled and cable tied. Avoid vibration contact areas as these may chaff the hose over time.7.3 Diesel fill. Remove the Fuel canister lid and fill it with diesel taken from the storage tank. The engine must now be primed to remove any air from the system.7.4 Oil Fill canister. Remove the Oil canister lid and fill with the same oil which is been used in the generator itself. Depending on the model Oil canister a extra 0.8 to 1.2 litres may be required.7.5 Oil Fill – FAD. Remove the small oil pin from the FAD and fill with oil. (fill via the small diameter pin and not the whole lid, it does not unscrew). Assuming all the levelling is done correctly the FAD may now be tested. Use a clean container and remove 1litre of oil via the ball valve system from the sump. The FAD should now slowly start to dispense oil back into the sump. Note it is only a trickle fill and may take several minutes to dispense 1 litre. Once concluded successfully return the oil back to the generator. If the FAD does not seem to be operating correctly pls see section #8 Trouble shooting. If the engine is a closed system meaning the sump has limited pressure within it also see section #8.7.6 Start the generator and check for all leaks etc.7.7 Replacing filter elements. Pls see the label instructions on the next page.

FAD been filled. Note the silver lid does NOT screw off. The FAD plunger must be hand tightened only.

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Superior Filtration Systems

Part number FC-1000

http://www.filtek.co [email protected]

FUEL CANISTER

* Use only Filtek RE-1000 element

RECOMMENDED TIMEPERIOD FOR REPLACEMENT

Element Replacement:

Turn off the engine and wait 5 minutes for levels to settle. Loosen ‘T’ screw anti clockwise and remove the lid and rubber seal.

Extract the element from the canister. Use the extractor tool supplied via the security belt. The element may rotate back and forth for ease of removal.

Load a new element (security belt face up). Push down to bottom of the canister. Inspect and reposition the rubber seal onto the canister (not the lid).

Fill the canister with fuel to just below the rubber seal. Prime the fuel pump. Hand tighten the ‘T’ screw. Insert the used element in bag provided for disposal.

Step 2.

Step 3.

Step 4.

Step 1.

Replace element every +1,000 runtime hours and conclude a

standard service. Should interval not be achieved, clean the bulk fuel tank.

Superior Filtration Systems

Part number OC-1000

http://www.filtek.co [email protected]

OIL CANISTER

* Use only Filtek RE-1000 element

RECOMMENDED TIMEPERIOD FOR REPLACEMENT

Replace element every 1,000 runtime hours and conclude standard service.

Monitor gauge to indicate element replacement due.

Element Replacement:

Turn off the engine and wait 5 minutes for levels to settle. Warning HOT - use gloves. Loosen ‘T’ screw anti clockwise and remove the lid and rubber seal.

Extract the element from the canister. Use the extractor tool supplied via the security belt. The element may rotate back and forth for ease of removal.

Load a new element (security belt face up). Push down to bottom of the canister. Inspect and reposition the rubber seal onto the canister (not the lid).

Fill the canister with new oil to just below the rubber seal. (do not overfill). Hand tighten the ‘T’ screw. Insert the used element in bag provided for disposal.

Step 2.

Step 3.

Step 4.

Step 1.

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8. Trouble shooting the system & FAQ’s

The following aspects will be covered in this section:-8.1 Trouble shooting - Fuel System8.2 Trouble shooting – Oil System8.3 Trouble shooting – Filtek Auto-Oil Dispensing System

8.3.1 FAD principle of Operation on a closed generator system

8.1 Trouble shooting the fuel system. Assuming no leaks and correct connections very little can go wrong with this system.

a) Fuel starvation (blocked element) The engine is not getting sufficient fuel. Switch off the engine and do a physical inspection of the Filtek replacement element by removing the canister lid. If the element is clogged and the generator has only been running for a few hours the bulk tank is in urgent need of cleaning. Do not by-pass the fuel filter even in the case of emergencies as this very contaminated diesel fuel will most likely block the injectors causing significant down time and costs. In emergencies first pump out as much of the contaminants as possible from the bottom of the bulk tank and replace the element. Replacing the element will only provide a temporary solution and will most likely block again but should provide sufficient time and protection for the bulk tank to be cleaned.

b) Fuel starvation (flow rate). If the engine is not getting sufficient fuel and the replacement element is clean then the generator has exceeded the fuel canister flow rate. Add another fuel canister in parallel to the existing unit, this will effectively double the flow rate.

c) Fuel starvation (OEM filter). In instances where Filtek was installed at an existing problematic site, some contaminated fuel may be present in the system between Filtek and the OEM spin on filter. Purge and replace OEM filter. The average OEM spin-on filter is around 30 micron while Filtek offers 1 micron filtration. This effective places very little or no work load on the OEM filter hence its ability to now remain for 1,000hrs.

Taking a fuel sample from a existing storage tank will often result in a bit of a ‘shock’. Diesel will absorb the first small quantity of water it comes in contact with known as ‘emulsified water’ –Filtek will remove this. However larger contaminants and quantities of water will settle at the bottom of the tank which is the fuel supply to the generator. Using a hand pump remove this layer and preferably clean the entire bulk tank.

Hazed fuel

Bacteria

Water and sludge

Hand pump to remove water and sludge from the bottom of a bulk tank.

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8.2 Trouble shooting the Oil system. Assuming no leaks and correct connections again not much can go wrong with system.

To ensure the oil filter is working correctly after a few minutes of operation touch the canister (caution HOT), it should be the same temperature as the engine. This will indicate correct oil flow. The gauge on canister known as the ‘Element Gauge’ and measures the resistance between the input and output. (It is not a measure of engine pressure). As the element becomes saturated with contaminants so too will the pressure gauge reading will increase. High viscosity fluids will naturally present more resistance. The gauge offers a visual inspection of the condition of the element without opening the canister. Normal operation would be in the green area. High readings will indicate the filter element is blocked and severely restricting oil flow - no longer working effectively. Action: element replacement due.

Q: Does Filtek void my OEM warranty or change engine oil pressure in anyway.

A: NO it does not.

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. Again you can check the filter is function correctly by checking that it is hot 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.

8.3 Trouble shooting – Filtek Auto-Oil Dispensing System. Assuming no leaks and correct connections :-a) FAD is over filling. The FAD is dispensing oil above the OEM prescribed level. In this case the

FAD is mounted to high. Often it is best to leave the generator off and allow the FAD to continue to dispense oil until it stops. This over fill can then be measured on the dipstick and translated to the FAD’s height decrease.

b) FAD is not working (align centre pin). Remove the centre pin at the top of the FAD and ensure it is neatly seated in the reciprocal void. When the pin is removed from the FAD it will disengage and not dispense.

c) FAD is not working (low level). If the FAD is not dispensing oil and the pin is correct the FAD may to too low. Recheck all your height measurements or continue to remove oil from the sump in small increments until the FAD’s starts to dispense. Via the dipstick this will provide the height by which the FAD must be increased.

a) Oil from the engine is pushing the FAD level up. This condition will most likely indicate a ‘closed engine system’ which can often be confirmed from the manufacturer or indentificationof a breather at the top of the engine cover. For closed system a ‘aluminium non breather’ type FAD is recommended illustration bottom of page #6. For these system the principle of operation of the FAD is slightly varied. See 8.3.1 FAD principle of Operation on a closed generator system

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8.3.1 FAD principle of Operation on a closed generator system

Some generators have a ‘closed’ oil system meaning there is pressure present in the sump when the generator is running. Certain engine can be regarded as a high internal sump pressure which increases the level of the sump by up to 10mm between the off and running conditions.

full

low

65mm

10mm full

low

65mm

1) Generator ‘off’ – sump full 100% 2) Generator ‘running’ – sump full 100%

FAD – NOT dispense

10mm45mm

Actual sump level (if Generator where off)

4) Generator ‘running’ – sump 80%

full

low

FAD – dispenses OIL

Actual sump level (if Generator where off)

FAD – dispenses OILFAD – dispenses OIL

3) Generator ‘running’ – sump @ 90%

FAD – NOT dispense10mm

full

low

55mmActual sump level (if Generator where off)

FAD – dispenses OIL

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