How it Works
Separ Filter
Loading...
S
Loading...
Loading...
SWK-2000
Operating Manual
30 pgs1.57 Mb0

Separ Filter SWK-2000 Operating Manual

Download
Dok.-Nr.: D10029.EN Rev.: 11 Page 1 of 30
Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Operating Manual
Water separator / Fuel pre-filter SWK-2000
Dok.-Nr.: D10029.EN Rev.: 11 Page 2 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Table of contents
General information...................................................................................................... 4 1
1.1 Disclaimer ............................................................................................................................................ 4
1.2 Symbols used ...................................................................................................................................... 4
1.3 Safety instructions............................................................................................................................... 4
1.4 Intended use ....................................................................................................................................... 5
Introduction .................................................................................................................. 6 2
2.1 Why Separ ........................................................................................................................................... 6
2.2 Function of the SWK-2000 .................................................................................................................. 6
2.3 Fields of application of the filter ......................................................................................................... 7
2.4 Tests and Certificates .......................................................................................................................... 8
Delivery ........................................................................................................................ 9 3
3.1 Scope of delivery ................................................................................................................................. 9
3.2 Unpacking............................................................................................................................................ 9
3.3 Storage ................................................................................................................................................ 9
Technical description .................................................................................................. 10 4
4.1 General arrangement drawing .......................................................................................................... 10
4.2 Dimensions and weights ................................................................................................................... 12
4.3 Characteristics ................................................................................................................................... 12
4.4 Available options ............................................................................................................................... 13
4.5 Materials used ................................................................................................................................... 14
4.6 Electrical data .................................................................................................................................... 14
4.7 Mechanical connections ................................................................................................................... 14
4.8 Temperature ranges .......................................................................................................................... 14
Filter combinations ..................................................................................................... 14 5
5.1 Switch-over system ........................................................................................................................... 15
5.2 Double-unit system ........................................................................................................................... 17
Options ....................................................................................................................... 18 6
6.1 Filter heating ..................................................................................................................................... 18
6.1.1 Heating system SWK-2000/5/50, /10 and /18 .................................................................................. 18
6.1.2 Fuel pre heating system SWK-2000/40/MH or MHS ........................................................................ 19
6.2 Water in fuel sensor (WIF) ................................................................................................................ 21
6.3 Differential pressure switch .............................................................................................................. 21
6.4 Relative pressure switch ................................................................................................................... 21
6.5 Vacuum gauge ................................................................................................................................... 22
6.6 Bowl................................................................................................................................................... 22
Dok.-Nr.: D10029.EN Rev.: 11 Page 3 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Assembly .................................................................................................................... 23 7
7.1 Selection of mounting position ......................................................................................................... 23
7.2 Filter installation ............................................................................................................................... 23
7.3 Electrical connection ......................................................................................................................... 24
7.4 Disassembly ....................................................................................................................................... 24
Commissioning............................................................................................................ 25 8
Maintenance ............................................................................................................... 26 9
9.1 Tightening torques ............................................................................................................................ 26
9.2 Drainage of water ............................................................................................................................. 26
9.3 Back-flushing process ........................................................................................................................ 27
9.4 Element replacement ........................................................................................................................ 27
9.5 Cleaning ............................................................................................................................................. 28
Repair ......................................................................................................................... 28 10
Accessories ................................................................................................................. 29 11
Disposal ...................................................................................................................... 30 12
Annex B: Specific drawings .......................................................................................... 30 13
Dok.-Nr.: D10029.EN Rev.: 11 Page 4 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
General information 1
1.1 Disclaimer
The preparation of this document was made as carefully as possible. However, errors can not be excluded. Therefore, we do not take over any liability for errors or deficits in this document, nor for any consequential damages which may arise there from.
We reserve the right to make technical changes to this document or the product described herein without notice.
1.2 Symbols used
The following symbols are used in this document to visually emphasize important information and warnings:
Note
Note on special tips and other helpful or important information.
Attention
Disregarding these instructions may damage the fuel filter or the mashine where the filter is mounted.
Disposal
Note on special measures for protection of the environment / surroundings and disposal of the system or parts of the system.
1.3 Safety instructions
Wear goggles
Wear
protective
gloves
Ventilate the
work area
Refrain from
smoking
No open fire
No food in the
work area
Works on the system have to be performed by trained personal only and in compliance with the applicable work safety regulations. Generally operate on a cut-off, voltage-free system.
Dok.-Nr.: D10029.EN Rev.: 11 Page 5 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
The filter may be under pressure. Therefore never open a filter in operation, otherwise fuel may leak into the environment and the engine draws air, which can cause damage to the engine.
When using duplex or switchable filters, the lever position indicates which filter is in operation. At this moment the other filter is isolated from the fuel circuit, but still could contain fuel.
Filters with fuel pre heating systems may only be placed in operation when completely filled with fuel and primed of air.
The electrical current for the heater must never be turned on without grounding and activated associated control system.
Remove spilled fuel immediately and dispose them in accordance with the applicable statutory provisions (s. cha. 12).
1.4 Intended use
The filter is intended for the filtration of diesel fuels and mineral oils with a dynamic viscosity < 10 mPas, flash point > 55 °C and boiling point > 160 °C and is designed for operation in between fuel tank and fuel lift pump (suction side). The filter should never be installed on the pressure side, behind the fuel pump.
Dok.-Nr.: D10029.EN Rev.: 11 Page 6 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Introduction 2
2.1 Why Separ
In 1992, the generation SWK-2000 water separators / fuel filter was developed by the company W. Lösing Filtertechnik e. K. as an effective system for the separation of water and dirt particles which are contained in the fuel. Both water and dirt can lead to high wear and tear on engines as well as the injection systems and result in expensive, intensive repairs and equipment down time.
SWK-2000 offers:
Smallest and most compact design High separation efficiency Low flow resistance Long life filter element Easy installation Simple maintenance Different flow rates Minimal maintenance effort Enviroment friendly
2.2 Function of the SWK-2000
The separation and purification process using a special patented system that is used throughout all of the different sizes, which stick out through most compact design in relation to the effective flow rate.
Generally, the SWK-2000 is installed on the vacuum side of the fuel system, i. e. between fuel tank and fuel pump.
The fuel enters the filter through one of the two inlet parts, the unused port must be sealed off with the attached plug.
Stage 1
From the inlet port, fuel flows into the filter and passes an interior vane system whereby the fuel is moved in an intensive circular motion.
Stage 2
The centrifugal gravity, resulting from the circular motion, forces the fuel to the outer wall of the bowl. The heavier water droplets and heavier particles collect on the wall of the bowl and settle due to natural gravity to the bottom of the bowl.
Dok.-Nr.: D10029.EN Rev.: 11 Page 7 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Stage 3
In the further flow the fuel passes the outer vane system. By the different length of the vanes and the twofold change in the fuel flow direction, smaller water droplets and fine dirt particles settle on the vanes, where they agglomerate and than decline, caused by gravity, down to the bottom of the bowl. Already at this point the major portion of any contaminates in the fuel have been separated.
Stage 4
Below the filter element, on the so-called dome, the flow cross-section is considerably increased, whereby a slow-down of the fuel occurs. This also allows smallest water droplets and dirt particles to settle. Through the previous pre-separation, the majority of the contamination (water and dirt) settles in the bowl and prolongs significantly the lifetime of the filter element.
Stage 5
The remaining suspended contamination in the fuel, finest water droplets and smallest particulates are filtered by a replaceable filter element which is produced from a special cellulose paper or stainless steel mesh elements.
The clean fuel leaves the filter through one of the outlet ports (the port not required should be sealed off with the plug attached) and continues through thefuel system.
2.3 Fields of application of the filter
Vehicle industry – trucks, busses, crane trucks, municipal vehicles, etc. Construction machinery, agricultural machinery, forklifts, compressors, etc. Ship propulsion motors, auxialliary units Stationary engines and generators, welding and pumping units Mining machinery, rail vehicles
Dok.-Nr.: D10029.EN Rev.: 11 Page 8 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
There are also versions available for special applications.
Specifically for marine or prime power application duplex or switchable filters are offered. Thereby a filter can always be serviced, while the other filter is under flow without engine shut down.
For engines burning biodiesel appropriate versions are available.
For winter operation the SWK-2000 filter is available with pre-heating systems.
For hot environments there are custom high-temperature variants available.
2.4 Tests and Certificates
The SWK-2000 has various approvals and certificates. Copies can be provided on request. Below is a list of organizations that have carried out these tests.
Rheinisch-Westfälischer TÜV KBA - Kraftfahrt-Bundesamt Flensburg German Technical Department for Army Ship and Marine Weapons GL - Germanischer Lloyd Type Approval Certificate Bureau Veritas Type Approval Certificate RINA ABS – American Board of Shipping LR – Lloyds Registry London Gost Standard Fire Resistance Test by MPA – Material Prüfungsamt NRW
Dok.-Nr.: D10029.EN Rev.: 11 Page 9 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Delivery 3
3.1 Scope of delivery
Check if you have the following accessories:
3.2 Unpacking
Before opening check the delivery for outer damage.Report any damage to carrier.
DISPOSAL
Please follow the environmental guidelines and laws of your country. Make sure the the packaging material is disposed according to applicable regulations.
3.3 Storage
The filter and its accessories must be kept dry and in compliance with the maximum permitted temperature ranges (s. chap. 5.8).
During a long storage period you should close all openings on the filter in order to protect the interior and the filter element from unnecessary pollution. All filters out of the factory have all ports sealed with plastic plugs.
Filter assembly
(s. chap. 4.1)
Operating instruction
Filter element
(already installed)
specific drawings
(upon request)
2 plugss
Dok.-Nr.: D10029.EN Rev.: 11 Page 10 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Technical description 4
4.1 General arrangement drawing
Using the example of the SWK-2000/10:
FilterLid Filter housing
Bleed screw
Mounting bracket
Mounting hole
Fuel inlet
(similar to the right filter side)
Fuel outlet
(similar to the right filter side)
bowl
Thread for water in fuel sensor
(on the right side)
Drain valve
Socket for heater control
Dok.-Nr.: D10029.EN Rev.: 11 Page 11 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Using the example of the SWK-2000/40/M/H:
Example of a filter element:
The filter shown here may differ from your purchased filter. The actual appearance and arrangement of the components depends on the configuration of the filter you have chosen.
Filter lid
Filter housing
Bleed screw
Mounting
Mounting hole
Fuel inlet
(similar to the left filter side)
Fuel outlet
(similar to the left filter side)
Bowl
2 sealed ports for water in fuel sensors
Drain valve
Heating electronics
(optional)
Connector for heater
Socket for heatercontrol. Note to be connected before heater plug
Grounding point
top
bottom
Handle as replacement aid
Dok.-Nr.: D10029.EN Rev.: 11 Page 12 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
4.2 Dimensions and weights
SWK-
2000/5
SWK-
2000/5/50
SWK-
2000/10
SWK-
2000/18
SWK-
2000/40
SWK-
2000/130
Width
140 mm
/WSA:
210 mm
140 mm
150 mm
/WSA:
220 mm
210 mm
290 mm
420 mm
Hight
275 mm
310 mm
340 mm
410 mm
470 mm
720 mm
Depth
90 mm
90 mm
110 mm
165 mm
250 mm
370 mm
Weight
< 2,5 kg
< 2,7 kg
< 3 kg
< 8 kg
< 15 kg
< 55 kg
Mountig holes
2 x Ø 9 mm
2 x Ø 9 mm
2 x Ø 9 mm
4 x Ø 9 mm
4 x Ø 12 mm
8 x Ø 15 mm
The dimensions of filter combinations may differ (see Chapter 5)
4.3 Characteristics
SWK-
2000/5
SWK-
2000/5/50
SWK-
2000/10
SWK-
2000/18
SWK-
2000/40
SWK-
2000/130
Flow performance
5 l/min
5 l/min
10 l/min
18 l/min
40 l/min
130 l/min
Complete interior volume
450 ± 30 ml
700 ± 35 ml
1200 ± 50ml
3100 ± 90ml
7000 ± 200
ml
40 ± 1 l
Water-holding capacity
120 ± 10 ml
120 ± 10 ml
240 ± 20 ml
500 ± 30 ml
1500 ± 50
ml
8,5 ± 0,5 l
Alarm on water quantity
80 ± 10 ml
80 ± 10 ml
140 ± 20 ml
300 ± 30 ml
1250 ± 50
ml
7 ± 0,5 l
Water-holding capicity with heater
-
100 ± 10 ml
200 ± 20 ml
450 ± 30 ml
1100 ± 50
ml
-
Alarm on water quantity (with heater)
-
70 ± 10 ml
140 ± 20 ml
300 ± 30 ml
1) 350 ± 50 ml
2) 950 ± 50 ml
-
Max. allowable pressure
15 bar
15 bar
12 bar
7 bar
4 bar
2 bar
Water separation
> 99 % des freien Wassers1
Available filter units
10 µm (coated cellulose paper) 30 µm (coated cellulose paper)
30 µm (stainless steel mesh) 60 µm (stainless steel mesh)
The characteristics of filter combinations may differ (see Chapter 5)
1
The water separation was detected at W. Lösing Filterproduction GmbH based on the DIN 4020 and the
ISO-TS 16332.
Dok.-Nr.: D10029.EN Rev.: 11 Page 13 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Pressure drop2
4.4 Available options
SWK-2000/5
SWK-2000/10
SWK-2000/18
SWK-2000/40
SWK-2000/130
heating
x3 x x x -
Water sensor
x x x x x
Relative pressure switch
x x x x X
Differential pressure switch
x x x x x
Clogging indicator
x x x x x
Transp. bowl
x x x - -
Metal bowl x x x x
X
Heavy-Duty design
x
Not applicable because only Heavy-Dutiy version available.
2
All pressure losses were measured with diesel according to EN590 at 20 °C ± 2 °C fuel and ambient
temperature.
3
Only in connection with option /50
Pressure drop of SWK-2000/5
Flow rate [l/min]
Flow rate [l/min]
Pressure drop of SWK-2000/10
Flow rate [l/min]
Pressure drop of SWK-2000/18
Flow rate [l/min]
Pressure drop of SWK-2000/40
Dok.-Nr.: D10029.EN Rev.: 11 Page 14 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
4.5 Materials used
Filter cover, filter housing
Aluminium
Bowl
Aluminium or transparent PA
Drain valve
Brass, PBT
Gaskets
TPE and/or HNBR
Bleed screw
Steel
Outboard screws
Stainless steel A2
4.6 Electrical data
Electrical components are installed only in conjunction with a filter heater, water in fuel sensor and/or pressure switch. The electrical data on these options please refer to chaptures 6.1 and 6.2. Filter sizes for which the above options are available please refer to chapture 4.4.
4.7 Mechanical connections
SWK-2000/5
SWK-2000/10
SWK-2000/18
SWK-2000/40
SWK-2000/130
Fuel inlet
M16x1,5
M22x1,5
M26x1,5
M33x2
G2“
Fuel outlet
M16x1,5
M22x1,5
M26x1,5
M33x2
G2“
Recommended minimum-diameter performance
8 mm
12 mm
20 mm
26 mm
40 mm
The dimensions of filter combinations may differ (see Chapter 5)
Adapter for the fuel inlet and fuel outlet can be obtained as an accessory through the W. Lösing Filtertechnik e. K..
4.8 Temperature ranges
Filters are designed to operate in temperature range of -40 °C to 80 °C.
On the filter with fuel pre heating system, selected thermal fuses are installed. Fuses will be irrevocably destroyed when ignoring the stated temperature limit.
Filter combinations 5
In some areas of application it may be necessary to combine two structurally identical filters with one another. Currently, two different combination options are offered.
Dok.-Nr.: D10029.EN Rev.: 11 Page 15 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
5.1 Switch-over system
A switch-over system (marked in the product key through the addition /U) is a redundant Separ filter structure. The redundant system ensures uninterrupted operation of the filter system (e.g. during maintenance work on the filter).
Example of a switch-over system4:
Both filters have a common fuel inlet and a common fuel outlet. Using the switch-over lever, the filter through which the fuel should pass can be changed. The other respective filter is now no longer part of the fuel circulation and can be emptied and opened for maintenance purposes (see Chapter
9). Operation of the switch-over system in other lever positions to those shown in the following diagram is not permitted (move the lever only to the right or to the left as far as it will go)!
Left filter is active
Right filter is active
4
Example includes special options
The standard inlets and outlets remain closed
Fuel inlet
Fuel outlet
Switch-over lever
Dok.-Nr.: D10029.EN Rev.: 11 Page 16 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Deviations to Chapter 4.2 Dimensions and weights
SWK-
2000/5/U
SWK-
2000/5/50/U
SWK-
2000/10/U
SWK-
2000/18/U
SWK-
2000/40/U
SWK-
2000/130/U
Width [mm]
440
440
460
630
800
1,100
Height [mm]
300
340
380
450
530
860
Depth [mm]
160
160
200
230
280
430
Weight [kg]
< 8
< 8
< 10
< 20
< 40
< 120
Fixing holes [mm]
2x slotted
holes (18x9)
Distance
apart: 416
2x slotted
holes (18x9)
Distance
apart: 416
4x slotted
holes (18x9)
Distance
apart: 435x85
4x slotted
holes (24x12) Distance
apart:
590x80
4x slotted
holes
(24x12)
Distance
apart: 760x100
16x slotted
holes (27x15)
Distance
apart:
See drawings
All sizes and weights may vary according to the precise configuration of the filter assembly. The exact
dimensions should be taken from the specific drawing of your filter.
The performance characteristics from Chapter 4.3 retain their validity for each individual filter.
Deviations to Chapter 4.7 Mechanical connections
SWK-
2000/5/U
SWK-
2000/10/U
SWK-
2000/18/U
SWK-
2000/40/U
SWK-
2000/130/U
Fuel inlet and outlet
Union nut with a cutting ring for a pipe with an external diameter of
G2“
12 mm
15 mm
22 mm
35 mm
Dok.-Nr.: D10029.EN Rev.: 11 Page 17 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
5.2 Double-unit system
In the case of a double-unit system, two identical filters are installed parallel in the fuel circulation. By parallelising the filter, the double-unit system is able to achieve twice the flow rate as that of a single filter.
Example of a double-unit filter system4:
Deviations to Chapter 4.2 Dimensions and weights
SWK-2000/40/2
SWK-2000/130/2
Width [mm]
870
1.100
Height [mm]
480
860
Depth [mm]
240
370
Weight [kg]
< 35
< 120
Fixing holes [mm]
4x slotted
holes (24x12)
Distance apart: 835x100
16x slotted holes (27x15)
Distance apart:
See drawings
All sizes and weights may vary according to the precise configuration of the filter assembly. The
exact dimensions should be taken from the specific drawing of your filter.
4
Example includes special options
The standard inlets and outlets remain closed
Fuel inlet
Fuel outlet
Dok.-Nr.: D10029.EN Rev.: 11 Page 18 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Deviations to Chapter 4.3 Characteristics
SWK-2000/40/2
SWK-2000/130/2
Flow rate
80 l/min
260 l/min
Total interior volume
14 ± 0.2 l
80 ± 1 l
Water absorption capacity
3 ± 0.05 l
17 ± 0.5 l
Water volume alarm
2.5 ± 0.05 l
14 ± 0.5 l
Deviations to Chapter 4.7 Mechanical connections
SWK-2000/40/2
SWK-2000/130/2
Fuel inlet and outlet
Union nut with a cutting ring for a pipe with an
external diameter of 42 mm
G3“
Options 6
Please refer to chapture 5.4 which options are available for your filter.
6.1 Filter heating
Different heating coils are used as a heating element in the different filter sizes. The heating of the filter size SWK-2000/40 is treated separately in one of the following chaptures. Heating controls of SWK 2000/40/MH are operating differently than models SWK 2000/5/50/H, SWK 2000/10/H and SWK-2000/18/H.
6.1.1 Heating system SWK-2000/5/50, /10 and /18
Types of fuel pre heating sytems
Operating voltage Heating power rating 12 VDC 250 W 24 VDC 300 W 24 VDC 450 W
Heating connection
Connectors
Pin 1
GND
Pin 2
Control terminal
Pin 3
GND (not used for all types)
Pin 4
VCC (has to be protected by electric fuse)
When fuel temperature is <5 °C, the control signal is connected to ground. At temperatures >10 °C, the signal is interrupted.
4 2 1
3
Dok.-Nr.: D10029.EN Rev.: 11 Page 19 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
External interconnection
6.1.2 Fuel pre heating system SWK-2000/40/MH or MHS
In the heated filter of the SWK-2000/40 series, a heating power of 1400 W is fed into the fuel. The heating system is in a 230 V and a 440 VAC version available.
Attention
The heater voltage must always be switched to the filter via an external contactor with sufficient breaking capacity. The heater voltage may only be switched on when the contact between pins C and D (Hummel connector: 3 and 4) of the control terminal is closed. In case of interruption between pins C and D (Hummel connector: 3 and 4) the heater voltage must be switched off immediately! Other switching states can cause damage to the heating filter.
Control electronics
The control electronics are identical for all versions of the filters described here.
Operating voltage: 24 VDC Maximum operating voltage: 36 VDC Minimum operating voltage: 16 VDC Power input: < 10 W
Types of heatin systems
Operating voltage: heater power rating 230 VAC (50 Hz/60 Hz): 1400 W 440 VAC (50 Hz/60 Hz): 1400 W
Voltage by ignition key
Battery voltage
relay (e. g.: Bosch 0 332 019 150) for 12 V
relay (e. g.: Bosch 0 332 019 203) for 24 V
Rotary switch with
indicator light
Dok.-Nr.: D10029.EN Rev.: 11 Page 20 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Heating voltage connection
Connector: Harting
Pin 1
Heating voltage (see operating voltage from the heater)
Pin 3
Heating voltage (see operating voltage from the heater)
Pin 5
Protective conductor
Separate protective earth terminal
Old revision (stud M8)
New revision (lug with hole 8,5 mm)
Control connector (available with Cannon or Hummel connector)
Cannon:
Hummel:
Connector Cannon
Connector Hummel
Pin A
Pin 1
24 VDC (for control electronics)
Pin B
Pin 2
GND
Pin C
Pin 3
24 VDC (for external main contactor)
Pin D
Pin 4
Switching output for main contactor
Pin E
Pin 5
Connection to 6 (F) when error
Pin F
Pin 6
Medium changer connection (status)
Pin G
Pin 7
Connection to 6 (F) when heating OK
Pin 8
Not used
Pin 9
Not used
3
5 4 6
1
2
A C D B F G E
6 8 1 7 3
2
5
4
9
Dok.-Nr.: D10029.EN Rev.: 11 Page 21 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Simplified diagram of the heating system
6.2 Water in fuel sensor (WIF)
Multiple WIF sensors are available either Bedia or SEPAR designed.
All sensor parts of the SEPAR-series are potential free. The detection of water is by capacitive measurement principle.
The exact thechnical specifications for water sensors can be found in a separate manual.
6.3 Differential pressure switch
The pressure switch is fitted in the fuel line at both the inlet and the outlet, and outputs an electrical signal when the differential pressure produced by the filter exceeds a calibrated value. The pressure switch is used as an indicator for a highly contaminated filter element.
6.4 Relative pressure switch
The relative pressure switch is fitted at the outlet port and outputs an electrical signal when the vaccuum in the fuel line exceeds a calibrated value (measured against ambient air pressure). The pressure switch is used as an indicator for highly contaminated filter elements.
The function of the relative pressure switch is the same as the differential pressure switch. But the differential pressure switch is mounted at the inlet and the outlet port and can measure the differential pressure between inlet and outlet.
Dok.-Nr.: D10029.EN Rev.: 11 Page 22 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
6.5 Vacuum gauge
The vacuum gauge is mounted in the outlet line of the filter and measures negative pressure (vacuum) downstream of the filter. You can use the vacuum gauge as a pollution indicator for the filter element.
To use the gauge as pollution filter you have to install an unused filter element to the filter. Launch the filter system and adjust the drag indicator to the preset value. We recommend to set a pressure rise of 200 mbar as alarm value.
6.6 Bowl
Plastic bowls (PA) are standard for SWK 2000/5, SWK 2000/10 and 2000/18. Aluminium bowls are available for those models as an option.
For models SWK 2000/40 and SWK 2000/130 only aluminium is available.
The advantage of transparent plastic bowl is that you can evaluate the water level and the degree of contamination of the collecting area without sensors.
The metal bowl is for harsher requirements and is resistant to broader range of temperatures and chemicals.
Dok.-Nr.: D10029.EN Rev.: 11 Page 23 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
> 60 mm
Assembly 7
7.1 Selection of mounting position
The SWK-2000 should be installed in an easily accessible location in the suction line of the fuel system between fuel tank and fuel pump. Any combination of inlet and outlet ports can be used.
NOTE
A shut off valve is always recommended in between the tank and the filter. If the filter is postioned below the tank (position 2), there is always a slight pressure on the fuel inlet of the filter, which can facilitate the priming of the filter.
NOTE
When the filter is positioned higher than the tank (position 1), we recommend the hand priming pump of W. Lösing Filtertechnik e. K. (s. chap. 11) to be mounted in the fuel line.
Please note that the filters have to be installed on an even surface..
When installing the filter sufficient space of at least 60 mm above the filter lid must be allowed.
Below the filter sufficient space must be left to either place a suitable container for draining bowl or to attach a hose directly to the drain valve to allow drainage of water out of the filter.
7.2 Filter installation
Install the filter with the back against a sufficiently stable and flat surface. Depending on the filter option the SWK-2000 offers two or four holes (s. chap. 4.1) for mounting the filter: The diameter of the mounting holes can be found in the technical data (s. chap. 4.2).
Subsequently, the fuel ports are connected. There are ports for inlet and outleton either side of the filter housing. Matching fittings and adapters are a neccessity please consult section 5.7 for port size.
Tank position 2
Tank position 1
Shut-off valve
SWK-2000
Fuel feed pump
Injection system
Engine
Dok.-Nr.: D10029.EN Rev.: 11 Page 24 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Ensure in the design of the fuel lines that the radii of the curve segments are greater than 5-times pipe diameter in order to keep flow turbulence to a minimum.
7.3 Electrical connection
In its standard version, the SWK-2000 requires no electrical connections. Only when options with electrical connections are selected, such as filter heater, water sensor and pressure switch, the filter must be wired. For details see the appropriate subsections chapture 6.
7.4 Disassembly
Turn off the engine.
Set a suitable container under the drain valve.
Close shut off valves from tank. Open the bleed screw on the filter lid and then the drain valve. Let the filter run empty.
Remove the inlet and outlet pipes from the filter. Make sure that any still existing fuel can also flow into the provided container, to avoid pollution of the environment. Fuel leaking into the environment should be collected directly by an absorbent rag.
Loosen the screws on the rear panel and remove the filter carefully.
Dispose of the filter and the fuel and the materials needed (e. g. rag) in accordance with chapture 12.
Dok.-Nr.: D10029.EN Rev.: 11 Page 25 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Commissioning 8
After the filter has been installed in accordance with chapture 7, it can be put in operation.
1. Make sure that a filter element is inserted in the filter and check if all the openings of the
filter are sealed.
2. Rotate the drain valve several times to ensure that no contamination blocks closing of the
drain. Make sure that the drain valve is engaged in "closed" position.
3. Lay rags out to hold small amounts of fuel.
4. Open, if available, the shut off valve before the filter.
5. Loosen the bleed screw cautiously about 1-2 turns. Never turn the screw all the way out!
6. For priming of the fuel system use fuel priming pump.
7. Once the first small amounts of fuel come out of the bleed screw, tighten the screw again
(observe the tightening torque, see chapture 9.1).
8. Turn hand priming pump in flow position
9. Start the engine.
Dok.-Nr.: D10029.EN Rev.: 11 Page 26 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Maintenance 9
For all maintenance works pay attention on providing suitable container under the SWK-2000 to catch spilled fuel and for proper disposal (s. chap. 12).
Basically, the housing of the Separ filter is maintenance free. The maintenance is restricted to removal of accumulated water in the bowl and to regular replacement of the filter element.
When screws of the filter are loosen and tightened again, please observe the tightening torques (s. chap. 9.1).
9.1 Tightening torques
The tightening torques listed to be strictly observed. Lid and bowl retainer ring screws have to be tightened in multipile turns and crosswise. Shown torques will result in no leakages of the filter and avoid damages to the filter.
Bolted assembly
Height
Thigthening torque
Bleed screw
M6
4 Nm
Cover screws
M6 x 30
8 Nm
Bowl screws
M6 x 25
8 Nm
9.2 Drainage of water
If you find accumulated water at the bottom of the bowl, or the water sensor (optional) has triggered an alarmwater has to be drained out of the bowl.
NOTE
You should, if water has collected in the bowl, not wait to long with the drainage, as within a few days visible biomass might be foundat the interface between water and diesel fuel. This defines itself as pollution to the bowl wall and can, if it dissolves, reduce the service life of the filter element.
The following describes how the drainage must be performed. Make sure that during the operation no fuel can escape into the environment. Collect the fuel and dispose it properly (s. chap. 12).
1. Shut down the engine.
2. Close, if available, the shut off valve before the filter. In case of switchable filters switch lever
to the other filter.
3. Open the bleed screw above the filter lod.
4. Open the drain valve. Water and dirt are flushed out of the bowl. Leave the drain valve open
as long until cleaned fuel leakes. Collect drained fluids in a container and dispose as per local regulations.
5. Close the drain valve and the bleed screw (observe the tightening torque, s. chap. 9.1).
Dok.-Nr.: D10029.EN Rev.: 11 Page 27 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
6. After the system has been primed, the engine can be restarted.
If the engine still shows power losses, replace the element.
9.3 Back-flushing process
If the filter element is clogged by dirt particles and currently there is no way to replace the element, back-flushing can be used as an alternative. Hereby a part of the collected dirt again can be washed out. Depending on the degree of contamination the performance of the filter element can be restored.
1. Turn off the engine.
2. Open the bleed screw on the filter lid.
3. Place a container under the drain valve.
4. Open the drain valve by push or pull of the handle and turn it to a vertical position.
5. The clean fuel, which is located on the clean above the filter element, then flows back
through the filter element and cleans the element from water droplets and fine dirt.
6. Drain as much fuel from the filter so that the dirt is flushed out of the bowl.
7. Rotate the drain valve several times to ensure that no contamination blocks closing of
the drain. Make sure that the drain valve is engaged in "closed" position.
8. Close the drain valve.
9. Close the bleed screw.
10. Prime the fuel system.
11. The engine can be re-started again.
If the engine still continues to show power loss, repeat the process or replace the element (s. chap
9.4).
9.4 Element replacement
The filter element of the SWK-2000 should be changed if resistance exceeds engine manufacturer’s specification, but at least once a year.
Replacement of the element:
1. Turn off the engine. In case of switchable filters switch lever to the other filter.
Dok.-Nr.: D10029.EN Rev.: 11 Page 28 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
2. Close, if available, the shut off valve before the filter.
3. Open the bleed screw on the filter lid.
4. Open the drain valve. Water and dirt are flushed out of the bowl. Leave the drain valve open
as long until cleaned fuel leakes. Collectg liquids in a container and dispose according to the local regulations
5. Rotate the drain valve several times to ensure that no contamination blocks closing of the
drain. Make sure that the drain valve is engaged in "closed" position.
6. Close the drain valve and the bleed screw (observe the tightening torque, s. chap. 9.1).
7. Loosen the screws on top of the filter lid in multiple turns and crosswise. Otherwise damage
may be caused to the lid and / or housing.
8. Take off the lid. Remove the spring casssette. Lift the filter element at the bracket located at
the element out of the filter. Dispose the filter element according to the requirements in chapture 12.
9. Insert the new filter element. It is important to make sure that the sealing surface is the
bottom and the “Separ” logo represents the front.
10. Insert the spring cassette.
11. Replace if necessary the lid seal and hold the sealing surface of the filter housing and the lid
seal clean. If a new gasket is not on hand, make sure that the seal is free from particles and slightly greased to ensure a perfect seal.
12. Put the lid back to its previous position and tighten the cover screws crosswise in multiple
turns (observe the tightening torque, s. chap. 9.1) to prevent damage and leaks.
13. After the system has been primed, the engine can be restarted (s. chap. 8).
9.5 Cleaning
Plastic bowl and gaskets shouldbe cleaned with diesel fuel only. Alcohol-containing detergents and solvents can damage plastic bowl and gaskets severely.
Repair 10
Actual spareparts list can be obtained from Willibrord Lösing Filtertechnik e.K. or your distributor. Please consider the recommendations/instructions given in chapter 7 for assembly and disassembly of the filter. Repairs that go beyond the replacement of parts must be carried out by W. Lösing Filtertechnik e. K. or an authorized company. W. Lösing Filtertechnik e. K. accepts no liability for any damage caused by unauthorized persons or organizations.
Dok.-Nr.: D10029.EN Rev.: 11 Page 29 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Accessories 11
A variety of accessories for the SEPAR filter can be obtained by Willibrord Lösing Filtertechnik or your distributor:
The hand priming pump can also be installed in the fuel line and will ease the priming process. It is recommended to use the hand priming pump when the filter is situated higher than the fuel tank.
The water sensor is available as an option (s. chap.6.2) and as a separate product. It triggers an alarm when the water level rises in the bowl and water should be drained. As a digital output signal are low-actice and high-active.
Dok.-Nr.: D10029.EN Rev.: 11 Page 30 of 30 Manual: Water separator / Fuel pre-filter SWK-2000
Willibrord Lösing
Filterproduktion GmbH
Disposal 12
Drain and remove the filter according to the instructions in chapture 7.4.
Disused fuel filtersmight contain harmful residues. As thesespillfuel filters have to be disposed as per the local regulations.
The previous rendered diesel-water-dirt mixture belongs to the waste oil containing waste. With diesel fuel saturated absorbent, rags, etc. should be collected in non-combustible containers with self-closing lid.
Dispose any waste according to local regulations.
Annex B: Specific drawings 13
Drawings for your personal filter configuration are compiled in a seperated document in case of request.
Loading...
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use