40 Filter

INSTRUCTION MANUAL
Automatic Metal-
Edge Filter
with Radial Scraper Cleaning
TYPE AF 72
Cast Type
Ident-No. of the Instruction Manual:
971.835.4
MAHLE Filtersysteme GmbH Bereich Industriefilter Postfach 13 09 74603 Öhringen Telefon +49 (0) 79 41 - 67-0 Telefax +49 (0) 79 41 - 67-4 29
1 Contents 2 Safety instructions
2.1 Safety instructions for installation and operat-
1 Contents .......................................................................... 2
ing personnel
2 Safety instructions.......................................................... 2
2.1 Safety instructions for installation and operating The operating manual contains the principal safety instruc-
personnel ......................................................................... 2 tions, which have to be observed during mounting, operation
2.2 Types of identification used in the Instruction Manual 2 and maintenance .
The noncompliance may result in risks for persons and
3 Glossary .......................................................................... 3 environment and machine resp. plant. In detail the non-
compliance may result in one of the following risks:
4 General information........................................................ 3
Malfunction of essential functions of the machine resp.
4.1 Manufacturer.............................................................. 3
plant and plant components.
4.2 User information (Instruction Manual) ........................ 3
Endangering of persons by electrical, mechanical, and
4.3 Rating plate ATEX ..................................................... 3
chemical influences.
5 Intended application ....................................................... 4 Endangering of the environment by leakage of danger-
ous substances.
6 Functional description ................................................... 4
6.1 Principle of the process.............................................. 4 Before mounting/starting:
6.2 Main components of the metal-edge filter .................. 5 • Read operating manual.
6.3 Functional principle of a metal-edge filter................... 5 • Train mounting and operating personnel sufficiently.
7 Technical data................................................................. 6 • Ensure, that the responsible personnel understands fully
7.1 Explosion protection................................................... 6 the contents of the operating manual.
7.2 General data .............................................................. 6 • Make clear decisions about responsibilities and liabilities.
8 Transport and storage.................................................... 6 During operation of the plant:

• Keep the operating manual available at the place of use.
9 Installation....................................................................... 7 • Observe safety instructions.
9.1 Mechanical installation ............................................... 7 • Operate plant only in accordance with the power rating
9.2 Special installation instructions for the drain pipe....... 7 data .
9.3 Electro-pneumatic connections .................................. 7
9.3.1 Connection to customer's control ...................... 7 In case of unclarities:
9.3.2 Connection to MAHLE control (optional) ........... 8 • Contact the manufacturer.
9.4 Control variants.......................................................... 8
10 Start-up .......................................................................... 9 2.2 Types of identification used in the Instruction
10.1 Functional test.......................................................... 9 Manual
10.2 Programming the operating settings ........................ 9
11 Normal operation ........................................................ 10 Danger! Non-observance can result in
12 Shutting down the metal-edge filter.......................... 10 serious or fatal injury!
12.1 Temporary shut-down ............................................ 10 DANGER!
12.2 Prolonged shut-down (> 48 h)................................ 10
12.3 Emergency shut-down ........................................... 10 Warning! Non-observance can result in
13 Troubleshooting ......................................................... 10 personal injury or property damage!
WARNING!
14 Maintenance ................................................................ 10
14.1 Inspection and maintenance schedule ................... 11
Warning! Non-observance can lead to
14.2 Removing the filter insert ....................................... 11
damage to technical equipment!
To install .................................................................... 12
14.3 Cleaning the filter ................................................... 12 CAUTION!
14.3.1 Cleaning the filter insert .................................. 12 Safety instructions for work on live
14.3.2 Cleaning the filter casing................................. 12 equipment! All work must be carried out
14.4 Replacing the filter element.................................... 12 by a suitably qualified electrician.
14.5 Replacing the scraper ............................................ 13
Hand symbol, indicates general notes and
14.6 Replacing the stuffing box...................................... 13
information.
15 Manufacturer´s declaration ........................................ 15
16 Evidence of conformity .............................................. 16 General notes and information about pollu-
tion conservation.
17 Index ............................................................................ 17
18 Spare parts drawing ................................................... 18 • Bullet, indicates the order in which actions
are to be carried out.
19 List of spare parts....................................................... 19
Arrow, indicates the response of the ma-
chine/system to operator actions.
Page 2
Instruction Manual Metal-Edge Filter Type AF 72G, MAHLE Filtersysteme GmbH, 02.03.04, ID No. 971 835 4, Revision 05
3 Glossary 4 General information
Aerosol: 4.1 Manufacturer
Distribution of minute liquid droplets (or solid particles) in a
gas acting as the outer phase. MAHLE Filtersysteme GmbH
Schleifbachweg 45
D-74613 Öhringen
Agglomerate: Tel.: +49 (0)79 41 67-0
Structure made up of several small particles which have
Fax.: +49 (0)79 41 67-4 29
formed a ball (conglomerated) as a result of physical
forces.
4.2 User information (Instruction Manual)
CLM: MAHLE ID No. of this Instruction Manual.:.......... 971.835.4
Cooling lubricant in accordance with DIN 51385. Date: .................................................................... 02.03.04
Revision: ......................................................................... 05
Concentrate:
Quantity of residues enriched with solids. Emptied out of 4.3 Rating plate ATEX
the filter periodically. Further treatment may be necessary,
depending on the application.
Differential pressure (∆p):

Difference between the pressure on the muddy side and II 2 G c T3
the pressure on the clean side. 1. 2. 3. 4. 5.
Filter cake: 1. II Applies to surface applications

Layer that is built up from the solids retained on the surface
of the filter element. 2. Use in: Zone 1+2 Zone 2
2 3
Filter element (cartridge/split tube): 3. Atmosphere
Cylindrical body comprising a profiled support tube with G = Gas G G
triangular wires wound or welded onto it. The suspension D = Dust
that must be filtered flows inwards. Solids are retained on
4. Degrees of protection
the outer surface of the filter element.
C = Design safety
Filtrate: 5. T3 = The maximum surface temperature of the filtra-
Filtered substance. tion device is 200°C
Filtration mode:
The metal-edge filter operates normally and the drain valve
is closed.
Homogenization:
Unification of a system of substances.
(Field for rating plate)
Initial differential pressure:
Differential pressure at the start of the filtration process
(when the filter element is "clean").
Pilot control:
(5/2-way) valves actuated by the control, which switch
pneumatic control valves.
Suspension (raw suspension):

System of substances that must be filtered, generally con-
sisting of solids in a liquid. (Field for rating plate according to ATEX)
Syphon:
U-shaped pipe. A syphon cannot be drained without a con-
trol valve.
Explosion protection is only valid in conjunction with the
declaration of conformity.
Page 3
5 Intended application 6 Functional description
MAHLE metal-edge filters are designed for filtering liquids or 6.1 Principle of the process
pastes with a viscosity of up to 500,000 mPas. They can be
cleaned without interrupting operation. The cleaning process Filtration
can be either manual or automatic. A triangular-shaped wire is wound immovably on a threaded,
profiled support tube. The thread lead determines the gap
Types of application: width and thus the fineness of the filter. The suspension
• CLM filtration flows inwards through the filter element. The particles settle
• Product filtration on the outside of the element. The triangular geometry re-
sults in a significant increase in the cross-section after the
• Pre-separation within filter cascades
narrowest gap. Clogging is thus practically impossible.
• Protective filtration before or after certain process steps
• Process filtration
• Homogenization of agglomerates Filter element
This filter is only allowed to be used in accordance

with the operating conditions specified in the con- Profiled support tube
tract documentation and in the Instruction Manual.
All forms of use which deviate from or exceed the Narrowest gap
limits of use described above are considered to be
contrary to the intended purpose. The manufacturer
shall not be liable for any damage resulting from
such use.
PROHIBITED:
• Use for other purposes without prior
consultation with the manufacturer.
• Use in potentially explosive atmos-
pheres unless explicitly mentioned in
the contract documentation.
DANGER! • Use with smouldering, burning or
sticky particles. Increase in cross-section
• Use with highly explosive filtering
liquids and pastes.
Conditionally allowed:
• Use of solvents (in consultation with
the manufacturer!)
• Reverse flow through the filter (pres-
CAUTION! Fig. 1: Principle of separation at the filter element
sure < 0.6 bar).
Cleaning
The particles that settle on the cartridge or on the split tube
cause the differential pressure between the muddy side and
the clean side of the filter element to increase.
If this pressure difference exceeds a (settable) limit value, a
cleaning process is started. The filter element begins to
rotate. The scraper scrapes the filter cake off of the filter
element.
Scraper Triangular
wire winding
Profiled
support
tube
Filter cake
Fig. 2: Cleaning
Page 4
Start of cleaning process 6.3 Functional principle of a metal-edge filter
The cleaning process can be started in the following ways :
• manually, 1
• with the differential pressure switch, The raw suspension flows into the metal-edge filter.
• by means of a time switch,
• by the control of a machine tool. 2
The suspension flows through the filter element.
6.2 Main components of the metal-edge filter The particles settle on this element.
3
The filtrate enters the clean room and leaves the filter.
Fig. 3: Diagram of the main components
Ratchet for manual operation of the filter element

Suspension inlet
Connections for measuring differential pressure
Drain opening Fig. 4: Functional principle of a metal-edge filter
Gear motor for driving the filter element
4
Filtrate outlet The cleaning process is started either when the maximum
Filter casing differential pressure is reached (optional) or after a preset
Pneumatically or manually actuated drain valve time.
5
The filter element is rotated by means of the gear motor or
the ratchet. The stationary scraper scrapes off the sepa-
rated particles.
The filtration process is not interrupted.
6
The enriched particles on the raw side can be emptied out
periodically.
Page 5
7 Technical data 8 Transport and storage
Order-specific data Transport
• Always transport horizontally in the original packaging.
• Avoid vibrations.
Storage
• Always store horizontally in the original packaging.
• Always store in a dry, frost-free room.
Seaworthy packing is specified in the contract

This data is order-specific and can be taken from the rating documentation as an option.
plate.
7.1 Explosion protection
Possible explosion hazards:
If the dust removing equipment is installed in a poten-
tially explosive atmosphere
• INSTALLATION and OPERATION of

the metal-edge filter only in the cate-
gory specified in the contract docu-
mentation, offer/order confirmation!
• If no protection zone is specified: do
NOT attempt to operate the dust re-
moving equipment in a hazardous
area!
• The owner of the plant is responsible
for implementing the appropriate ex-
plosion protection measures.
• If in doubt, please consult the re-
sponsible inspectorate!
• The owner is responsible for zoning.
7.2 General data

Electrical power demand* ........... 250 VAC/400 V 3NPE
0.075 - 0.37 kW
Noise emission (peaks): ................................< 70 dB(A)
Dimensions:............................................ See data sheet
Min. height for dismantling above filter: ............. 515 mm
Total dry weight without valves: ............................. 30 kg
Max. permissible operating pressure:................< 16 bar
Max. permissible differential pressure
in the filter cartridge: ..........................................< 30 bar
Max. permissible differential pressure
in the split tube: .................................................< 10 bar
*See also rating plate of gear motor
Page 6
9 Installation 9.2 Special installation instructions for the drain
pipe
All installation work must be carried out
by suitably qualified personnel! The full inlet pressure is present at the
WARNING! drain valve!
WARNING!
The device is only allowed to be in-
stalled, accepted and tested by a suitably
• Make sure that the drain pipe is securely fastened.
qualified person (99/98/EC).
• Do not drain concentrate into the atmosphere.
• Provide splash protection if necessary.
9.1 Mechanical installation • Lay the pipes without a syphon if possible.
NOTE: Watch out for clogging as a result of sedimented con-
It must be possible to remove the filter insert in centrate!
order to carry out maintenance work. 9.3 Electro-pneumatic connections
• Prepare a suitable seat on which to mount the filter (e.g. All electrical installation work must be
supports). carried out by a SUITABLY QUALIFIED
• Be sure to allow the required height for dismantling and ELECTRICIAN in accordance with DIN EN
draining (see data sheet). 60204-1!
• Remove the metal-edge filter from the packaging.
• Bolt the metal-edge filter to the prepared seat
(2 x mounting hole D = 13 mm). 9.3.1 Connection to customer's control
• Bolt the metal-edge filter to the prepared seat. Gear motor
• Remove the caps from the connections. • See the rating plate or the contract documentation for
• Connect the pipes. the connection data (please also refer to the connection
Pressure relief diagram for the terminal box).
Design measures must be incorporated to prevent inadmis- • Connect the gear motor .
sible excess pressure on the muddy side. • Provide adequate protection for the motor.
• Install pressure relief devices if necessary.
• Check the conductivity between all

conductible components!
• Maximum permitted resistance
R < 10 Ω.
• Make sure that grounding is provided
by the customer.
400V 3~ 230V 3~
Dismantling height (≥ Fig. 6: Connection of the standard gear motor
515 mm)
Differential pressure switch (optional)
• Connect the differential pressure switch as a nor-
mally-open or normally-closed contact.
Inlet Filtrate See information in Appendix for contact rating.
Automatic drain valve (optional)
• Provide a suitable compressed air supply.
• Provide a suitable 5/2-way valve for pilot control.
Assembly See contract documentation for special types.

holes
D = 13mm
Drain Draining height

(400 - 600 mm)
Fig. 5: Mechanical installation
Page 7
9.4 Control variants
The cleaning control is dependent on the particular applica-
tion. The control variants1 and times specified here are
examples and are merely intended to serve as a guide.
Time-controlled cleaning, manual draining
T0 Time interval 60 s - 24 h
5/2-way valve
Compressed air
T0
= Pneumatic Cleaning
= Electrical Fig. 8: Time-controlled cleaning
Fig. 7: Electro-pneumatic connections Time-controlled cleaning and draining

T0 Time interval for cleaning 60 s - 24 h
RECOMMENDATION: T1 Time interval for drain valve 60 s - 24 h
Provide the following elements on the switch box: T2 Opening time of drain valve 2-5s
• Manual release for cleaning
• Manual release for drain valve
9.3.2 Connection to MAHLE control (optional) T1 T2

Drain valve
• Connect the incoming feeder, the gear motor, the differ-
ential pressure gauge (optional) and the pilot valves (op- T0
tional) in accordance with the enclosed circuit diagram. Cleaning
Fig. 9: Time-controlled cleaning/draining

Time-controlled cleaning,
counter-controlled draining
T0 Time interval for cleaning 60 s - 24 h
Z0 Cleaning counter 3-5
T2 Opening time of drain valve 2-5s
T2
Drain valve
T0
Cleaning
1 2 3 1 2 3 1
Z0
Fig. 10: Time-controlled cleaning, counter-controlled
draining
Differential pressure/time-controlled cleaning

T0 Max. time interval 6 - 30 s
T0
∆p signal
Cleaning
Fig. 11: Differential pressure/time-controlled cleaning
1
Mark the required control variant with a cross
Page 8
10 Start-up 10.2 Programming the operating settings
• Check that all the caps have been removed from the • Switch on the control.
connections. • Open the inlet.
• Remove all foreign particles from the filter. • Make a note of the initial differential pressure (optional).
• Check the pipe unions.
• Tighten the bolts. Settings for time-controlled cleaning
• Rinse the pipes. • Set the times according to the operating conditions and
This part is not allowed to be put into correct them if necessary.
operation until it has been established
that the machine in which it is be in- Settings for differential pressure-controlled clean-
stalled complies with the requirements ing with contact pressure gauge
of the applicable EC directives, harmo- • Adjust the differential pressure to the setpoint (see con-
DANGER! nized standards, European standards or tract documentation).
equivalent national standards.
• The filter must be fully vented if the
Initial differential pressures
The initial differential pressures are dependent on the par-
media used could generate explosive
ticular application.
gases.
General guide:
• The filter must be completely filled
Installation on discharge side: ∆p ≤ 0.3 bar
with fluid.
Installation on suction side: ∆p ≤ 0.03 - 0.1 bar
• Air inclusions must be eliminated.
10.1 Functional test
Direction of rotation of the gear motor
• Unscrew the cap of the gear motor .
• Start up the gear motor briefly (<1 s).
• Compare the direction of rotation of the shaft with that
shown by the arrow (clockwise direction). Filter on
• Reverse the terminal connections of the gear motor if discharge side
necessary.
• Screw the cap of the gear motor back on again.
Gear motor cap
Filter on
suction side
Fig. 13: Initial differential pressures
NOTE !
Fig. 12: Direction of rotation of the gear motor
After a cleaning process, the differential pressure
Check the differential pressure contact switch must return more or less to the original initial differ-
(optional) ential pressure.
• Adjust the contact to a differential pressure of "0". If it does not, the cleaning function is faulty (in this
The contact switch is switched. case, please consult the manufacturer).
• Turn the contact to the setpoint.
• See also information in Appendix.
Check the function of the drain valve (optional)
• Supply compressed air to the pilot valve.
• Actuate the manual release for the pilot valve.
The drain valve opens.
• Set the manual release to the OFF position.
The drain valve closes.
Page 9
11 Normal operation 13 Troubleshooting
The following must be monitored daily during normal opera-
Fault Possible cause Remedy
tion:
Gear motor Motor fuse tripped RESET motor fuse
• Differential pressure,
does not turn
• Concentrate tank level,
Check gear motor
• Control functions.
Filtrate solidified Clean filter
Valve does not Compressed air Increase pressure
RISK OF INJURY! open pressure too low
The filter is pressurized! Pilot valve defective
Check pilot valve
Do not allow concentrate to escape into Pilot valve not con-Check electrical
DANGER! the atmosphere (splash protection)! nected correctly and pneumatic
connections
Always dispose of concentrate in a manner Initial differential Solids concentra- Improve pre-
which does not pollute the environment! pressure no tion too high filtration process
Consult the responsible authorities before longer obtained Gear motor rotating Check direction of
deciding upon the most suitable disposal in wrong direction rotation
method. Cleaning time too Prolong cleaning
short time (min. gear
Cleaning the drain pipe motor speed: 1-2
revolutions)
Watch out for clogging if there is a high
Increased con- Filter element de- Check filter element
proportion of fine muddy particles and a
centration of dirt fective and if necessary
long pipe is used.
on clean renew
• Clean the pipe daily/weekly, depend-
CAUTION! side Seals brittle Check seals and if
ing on the application.
necessary renew
Leakage rate at Tighten shaft seal
To clean the drain pipe shaft seal too and if necessary
• Open the drain valve manually for approx. 10 - 15 s. high renew
The pipe is rinsed.
14 Maintenance
12 Shutting down the metal-edge filter
12.1 Temporary shut-down All maintenance work must be carried
out by a TRAINED ENGINEERING FIT-
On the control installed for the metal-edge filter: TER.
• Switch OFF the master switch. CAUTION!
12.2 Prolonged shut-down (> 48 h) Before all maintenance work:

• Shut down the automatic filter.
• Start a cleaning process manually. • Take steps to prevent the system from being switched
• Clean the metal-edge filter on again by unauthorized persons.
(see section 14.3 "Cleaning the filter", page 12 ).
• Fill the metal-edge filter completely with liquid.
• Switch OFF the master switch.
12.3 Emergency shut-down

• Switch OFF the master switch.
The power supply is interrupted.
Page 10
• Take any necessary safety precautions (protective cloth- 3
ing, goggles, etc.). • Close the compressed air supply.
4
• Disconnect the gear motor.
4
• Carry out the maintenance work.
• Start up the automatic filter again.
• Watch the automatic filter.
Does it operate normally? 2
• The accident prevention regulations

concerning work in potentially explo- 1 1
sive atmospheres must be observed
at all times!
• The owner of the plant is responsible
for implementing the appropriate ex-
plosion protection measures. 3
2
14.1 Inspection and maintenance schedule
• See also contract documentation Fig. 14: Disconnecting the filter
Assembly Activity Comments
5
Weekly Metal-edge Visual inspec- Leakage,
• Unscrew the bolts in the filter cover.
filter tion differential
pressure2
6
Pipes Clean
• Detach and remove the gear motor.
Monthly Filter Check, clean Wear
7
MAHLE Check conduc- < 10 Ω
• Apply a large screwdriver to the notch.
metal-edge tivity between all
filter system compo- • Lever off the filter cover.
nents.
Yearly or Bearings Visual inspec- Clearance 5
whenever tion
CLM is Valves Functional test
changed 6
Filter Clean
Seal kit
NOTE:
The necessary maintenance work is dependent on
the particular application. 7
Please consult the manufacturer if necessary.
14.2 Removing the filter insert
The filter is pressurized!

• First relieve the pressure!
• Then open the filter!
DANGER!
1
• Close the filter inlet and drain.
• Relieve the pressure in the pipe if necessary.
2
• Open the vent valve.
• Open the drain valve.
The filter is drained. Fig. 15: Detaching the gear motor and levering off the cover
2
Optional
Page 11
8 14.3.2 Cleaning the filter casing
• Pull out the filter insert vertically.
Do not tilt!
• Lay the filter insert down carefully on a level surface,
taking care not to damage the filter element.
• Take safety precautions appropriate to the hazard poten-
tial of the medium (e.g. goggles, respirator, protective
clothing, etc.).
• Remove any coarse impurities by mechanical means.
• Wash out the filter casing with a suitable detergent.
14.4 Replacing the filter element

The filter element must always be replaced by a
TRAINED MECHANICAL FITTER.
To remove the filter element

(the numbers correspond to those on the spare parts draw-
ing)
• Unscrew the hexagon nuts (36) and remove together
with the spring washers (35).
• Remove the centre flange (33).
• Unscrew the hexagon nut (40).
• Carefully pull the filter element (68) down and remove it.
35/36 40 33
Fig. 16: Filter insert
To install
In reverse order
• Lower the filter insert into position without tilting it.
14.3 Cleaning the filter

14.3.1 Cleaning the filter insert
• Take safety precautions appropriate to the hazard poten-

tial of the medium (e.g. goggles, respirator, protective Filter insert rotated 180°
clothing, etc.). Fig. 17: Removing the filter cartridge
• Remove any coarse impurities by mechanical means.
• Wash out the filter insert with a suitable detergent. To install the filter element
• Carefully blast the filter insert with a steam jet or com- • Oil the O-rings (17).
pressed air. • Check and clean the thrust washers (37), and if neces-
sary renew.
DANGER OF AEROSOL FORMATION ! • Install in reverse order.
Always work in rooms with a suitable
extraction system!
WARNING!
• Clean and oil the seals (and if necessary renew).
Page 12
14.5 Replacing the scraper 14.6 Replacing the stuffing box
Risk of fingers being crushed!
The scrapers are spring-loaded. Do not
reach into the gap between the scrapers
CAUTION! and the element!
• De-energize the gear motor and disconnect it.
• Unscrew the hexagon bolts (10) on the motor stator.
• Remove and clean the filter insert (see section 14.4
"Replacing the filter element", page 12). • Carefully lift the gear motor up and remove it from the
shaft.
• Unscrew the hexagon nut (36) and remove together with
the spring washer (35).
• Remove the centre flange (33). Hexagon bolts (10)
• Pull the scraper unit down and remove it.
• Unscrew the locking bolts (28) on the scraper (25).
• Replace the scraper (25).
Leg
spring (21)
Locking
bolts
(28)
Scraper
(25)
Leg Centre flange (33) Fig. 19: Removing the gear motor
spring (32)
Hexagon nuts
(35/36)
Fig. 18: Replacing the scraper
Important when installing the scraper:

• The leg springs (21/32) must rest in the slots provided.
• The scraper must rest cleanly against the filter element.
• The scraper must not be tilted.
• Check all screws and bolts, and tighten them if neces-
sary.
Page 13
• Unscrew the hexagon bolts (4).
• Remove the cover (6) and the sleeve (9).
• Remove the Belleville springs (7) and the gland (8).
• The packing rings (14) are now freely accessible and
can be replaced.
Hexagon bolts
(4) Cover (6)
Gland Belleville springs (7)

(8)
Packing rings (14)

Sleeve (9)
Fig. 20: Stuffing box accessible
To install the stuffing box

• Fit the stuffing box elements one at a time with an offset
of 180°.
• Fit the gland (8).
• Fit the cover (6) initially without the Belleville springs and
the sleeve, then tighten it carefully (the stuffing box ele-
ments are pre-compressed).
• Detach the cover again.
• Fit the Belleville springs (7), the sleeve (9) and the cover
(6).
• Tighten the hexagon bolts (4).
The stuffing box requires very little maintenance. Slight

leaking is perfectly normal and serves to lubricate the unit.
Page 14
15 Manufacturer´s declaration
The filter is only allowed to be started if the complete system is also started up !
16 Evidence of conformity
• The enclosed declaration of conformity for the Pressure Equipment Directive only applies to pressure
casings with a CE mark for categories I -IV !
• The standard version is designed for Group 2 liquids as defined by EC Directive concerning pressure
equipment 97/23/EC Article 9.
Page 16
17 Index
Leaking............................................................................. 12
A
M
Aerosol................................................................................3
Agglomerate .......................................................................3 Maintenance....................................................................... 2
Arrow ..................................................................................2 Manual release ............................................................... 6; 7
Manufacturer .................................................................. 2; 3
B Mounting............................................................................. 2
Bullets .................................................................................2 O
C Operating personnel ........................................................... 2
Cleaning..............................................................4; 5; 6; 7; 8 Operation............................................................................ 2
CLM filtration.......................................................................3 P
Compressed air ............................................................7; 10
Concentrate ................................................................3; 6; 8 Pilot control..................................................................... 3; 6
Contract documentation......................................................3 Pollution conservation ........................................................ 2
Control ................................................................................6 Power rating data ............................................................... 2
Control valves .....................................................................3 Pre-separation .................................................................... 3
Cross-sectional increase.....................................................4 Pressure difference ............................................................ 4
Pressure relief .................................................................... 6
D Profiled support tube ...................................................... 3; 4
Differential pressure........................................................3; 8 Protective clothing .............................................................. 9
Differential pressure switch .............................................4; 6 R
Direction of gear motor .......................................................7
Drain valve......................................................3; 4; 6; 7; 8; 9 Ratchet ........................................................................... 4; 5
Draining ..............................................................................7 Risks................................................................................... 2
E S
Environment........................................................................2 Safety instructions ..............................................................2
Safety precautions...................................................... 10; 11
F Scraper..................................................................... 4; 5; 11
Filter cake ...........................................................................3 Scraper unit ...................................................................... 11
Filter element ..................................................3; 4; 5; 10; 11 Seaworthy packing ............................................................. 5
Filter insert ........................................................................10 Splash protection................................................................ 6
Filter seat ........................................................................5; 6 Stuffing boxes............................................................. 11; 12
Supports ............................................................................. 5
G Suspension................................................................. 3; 4; 5
Syphon ........................................................................... 3; 6
Gear motor........................................4; 5; 6; 7; 9; 10; 11; 12
T
H
Time interval....................................................................... 7
Hand symbol .......................................................................2 Time switch ........................................................................ 4
Height for dismantling .........................................................5 Total dry weight .................................................................. 5
Height for draining...............................................................5
V
I
Viscosity ............................................................................. 3
Initial differential pressure ...............................................3; 8
Inlet .....................................................................................8 W
Installation on discharge side..............................................8
Installation on suction side..................................................8 Warning .............................................................................. 2
L
Leakage ..............................................................................2
Page 17
18 Spare parts drawing
(For standard version of carbon-steel filter insert)
Fig. 21: Spare parts drawing AF 724 (ID no.: 933.183.6)
Page 18
19 List of spare parts
(For standard version of carbon-steel filter insert)
8 Zyl.-Schraube DIN 912 M16x40 833 741 2 71 Cylinder-head bolt DIN 912 M16x40
2 Dichtung DIN 2690 PN40 001 358 1 70 Seal DIN 2690 PN40
2 Flansch DN40 PN100 836 896 1 69 Flange DN40 PN100
1 Filterelement See contract doc. 68 Filter element
1 Dichtungssatz für Stopfbuchspackung (FPM) 933 178 6 67 Nos. 17, 15, 14 (seal kit made of PTFE: 939 834 8)
1 Dichtungssatz für Lippendichtung 937 239 2 66 Nos. 17, 62, 61
1 Buchsensatz für Stopfbuchspackung 972 555 7 65 Nos. 37, 34, 16, 20, 29
1 Buchsensatz für Lippendichtung 972 556 5 64 Nos. 37, 34, 16, 20
1 Lippendichtung 937 237 6 62 Sealing lip
1 O-Ring 937 238 4 61 O-ring 17 8x2. 40
2 Buchse 933 175 2 16 Bearing bush
1 Lagerring 937 234 3 60 Bearing ring
1 Dichtungssitz 937 233 5 59 Seal seat
1 6kt.-Mutter DIN 934 M6 777 219 7 58 Hexagon nut DIN 934 M6

1 Senkschraube DIN 7991 M6x90 939 884 3 57 Countersunk screw DIN 7991 M6x90
1 Feder 933 225 5 56 Spring
2 Scheibe DIN 440 R6. 6 769 083 7 55 Washer DIN 440 R6. 6
1 Ventilteller 939 885 0 54 Valve retainer
1 Zentrierflansch 933 222 2 53 Centre flange
1 Abstreiferhalter 835 160 3 52 Scraper holder

1 Abstreifer (Elastopal) 835 161 1 51 Scraper
1 Abstreiftraeger 933 189 3 50 Scraper support
1 Bolzen D9 835 163 7 49 Bolt D9
5 Linsenschraube ISO 7380 M4x10 835 154 6 48 Oval-head bolt ISO 7380 M4x10
2 Spannstift DIN 1481 3x14 001 247 6 47 Dowel pin DIN 1481 3x14
1 Bolzen D7 835 164 5 46 Bolt D7
1 Gewindestift DIN 914 M6x8 763 487 6 45 Setscrew DIN 914 M6x8
1 Scheibe DIN 125 A8. 4 001 026 4 44 Washer DIN 125 A8. 4
1 Adapter 936 145 2 43 Adapter
1 Zahnradknarre 1/2“ 754 593 2 42 Ratchet 1/2"
1 Stange M10 939 870 2 39 Rod M10
1 Mitnehmer 930 424 7 38 Retainer
2 Anlaufscheibe 933 223 0 37 Thrust washer
3 Federring DIN 127 B8 001 084 3 35 Spring washer
1 Anlaufscheibe 930 496 5 34 Thrust washer
1 Zentrierflansch 933 180 2 33 Centre flange
1 Schenkelfeder unten 758 204 2 32 Leg spring
1 Spulenring 937 264 0 31 Cartridge ring
3 Distanzbolzen 832 287 7 30 Distance rod
1 Buchse 930 426 2 29 Bush
4 Sicherungsmutter DIN 980 M4 777 314 6 28 Locking bolt DIN 980 M4
4 6kt.-Schraube DIN 933 M4x20 763 549 3 27 Hexagon bolt DIN 933 M4x20
1 Abstreiferwelle 832 290 1 26 Scraper shaft
1 Abstreifblech 106 621 6 25 Scraper
1 Versteifungsblech 106 617 4 24 Stiffener plate
1 Spannhuelse 6. 0x30 DIN 1401 886 202 1 23 Dowel pin 6.0x30 DIN 1401
1 Spulendeckel Z 937 263 2 22 Cartridge cover
1 Schenkelfeder oben 765 041 9 21 Leg spring
2 Fuehrungsring 832 288 5 20 Guide ring
2 Dichtring DIN 7603 A14x18x1. 5 777 169 4 19 Sealing ring DIN 7603 A14x18x1.5
2 Verschlusschraube DIN 910 1/4“ 763 210 2 18 Plug DIN 910 1/4“
2 O-Ring 98x3. 5 756 550 0 17 O-ring 98x3. 5
1 Buchse 933 175 2 16 Bearing bush
1 O-Ring 30x2 933 165 3 15 O-ring 30x2
3 Packungsring 933 181 0 14 Packing ring
1 Lagerring 933 166 1 12 Bearing ring
1 Motorblock 933 403 0 11 Motor flange
4 6kt.-Schraube DIN 933 M16x50 001 151 0 10 Hexagon bolt DIN 933 M6x50
1 Huelse 933 193 5 9 Sleeve
1 Brille 933 168 7 8 Gland
8 Tellerfeder DIN 2093 B35. 5x18. 3 933 176 0 7 Belleville spring DIN 2093 B35. 5x18.3
1 Deckel 933 167 9 6 Cover
2 6kt.-Schraube Din 931 M6x55 930 401 5 4 Hexagon bolt DIN 931 M6x50
1 Antriebswelle 936 117 1 3 Motor shaft
1 Passfeder DIN 6885 A6x6x20 886 212 0 2 Adjusting piece DIN 6885 A6x6x20
1 Winkelgetriebemotor 930 398 3 1 Angle gear motor
Qty. Part name/DIN designation ID no. Ser.

no.
Please request a separate spare parts drawing and list of spare parts for special types.
Page 19
INSTRUCTION MANUAL
AUTOMATIC BALL DRAIN VALVE
with electro-pneumatic part-turn actuator
G 2“ 230 VAC 936.047.0
G 2“ 24 VDC 936.048.8
G 1“ 230 VAC 936.045.4
G 1“ 24 VDC 936.046.2
G¾“ 24 VDC 970.832.2
G ½“ 230 VAC 938.252.4
G ½“ 24 VDC 938.253.2
975.128.0
1 Contents 2.2 Types of identification used in the Instruction
Manual
1 Contents .........................................................................2
2 Safety instructions.........................................................2 Danger! Non-observance can result in
2.1 Safety instructions for installation and operating serious or fatal injury!
personnel ........................................................................2 DANGER!
2.2 Types of identification used in the Instruction Manual2
3 General information.......................................................2
3.1 Manufacturer.............................................................2 Warning! Non-observance can lead to
3.2 Specifications of the Instruction manual....................2 damage to technical equipment!
CAUTION!
4 Intended application ......................................................2
5 As-delivered condition ..................................................3 Safety instructions for work on live
equipment! All work must be carried out by a
6 Technical data................................................................3 suitably qualified electrician.
7 Mechanical design .........................................................3
• Bullet, indicates the order in which actions
8 Storage ...........................................................................3 are to be carried out.
9 Electro-pneumatic connections ...................................3
Arrow, indicates the response of operations
10 Start-up .........................................................................4
11 Maintenance during operation....................................4
12 Troubleshooting ..........................................................4 3 General information
3.1 Manufacturer
2 Safety instructions MAHLE Filtersysteme GmbH
Schleifbachweg 45
2.1 Safety instructions for installation and
D-74613 Öhringen
operating personnel Tel.: +49 (0)79 41 67-0
The operating manual contains the principal safety Fax.: +49 (0)79 41 67-4 29
instructions, which have to be observed during mounting,
operation and maintenance . 3.2 Specifications of the Instruction manual
MAHLE ID No..................................................... 975.128.0
environment and machine resp. plant. In detail the
Date: .................................................................... 10.02.04
noncompliance may result in one of the following risks:
Notice of change:............................................................ 04
Endangering of persons by electrical, mechanical, and 4 Intended application
The automatic ball drain valve drains the contents of the:
Endangering of the environment by leakage of
• MAHLE automatic filter
dangerous substances.
• MAHLE metal-edge filter
Before mounting/starting: • MAHLE axial filter
• Read operating manual. electro-pneumatically.
• Train mounting and operating personnel sufficiently.
• Ensure, that the responsible personnel understands fully This unit is only allowed to be used in
the contents of the operating manual. accordance with the operating
• Make clear decisions about responsibilities and conditions specified in the contract
liabilities. documentation and in the Instruction
During operation of the unit: Manual. All forms of use which deviate
• Keep the operating manual available at the place of use. from or exceed the limits of use
• Observe safety instructions. CAUTION! described above are considered to be
contrary to the intended purpose. The
• Operate plant only in accordance with the power rating
data . manufacturer shall not be liable for any
damage resulting from such use.
In case of unclarities:
• Contact the manufacturer . PROHIBITED:
• Use in potentially explosive atmospheres,
DANGER! unless explicitly mentioned in the contract
documentation.
Page 2
Instruction Manual Automatic Ball Drain Valve, MAHLE Filtersysteme GmbH, 10.02.04, ID No. 975 128 0, Revision 04
5 As-delivered condition 8 Storage
The automatic ball drain valve is supplied as a complete • Always store in the original packing.
unit mounted on the filter or as an additional set. It • Always store in a dry, frost-free room.
comprises:
a ball valve,
a pneumatic part-turn actuator (double-acting),
an electro-pneumatic 5/2-way valve.
6 Technical data
Electrical and mechanical connections 9 Electro-pneumatic connections
see front page All electrical installation work must be
carried out by a SUITABLY QUALIFIED
Pneumatic connection ELECTRICIAN in accordance with DIN EN
Control medium: ............ Compressed air, dehydrated, oiled 60204-1!
Control pressure: ...................................................6 to 8 bar
Temperature of control medium: .................. -10°C to +50°C
Connection:...................................................................G ¼" Double-acting,
part-turn actuator
Operating data of the ball valve Ball valve
Operating pressure: ................................................ < 40 bar
Operating temperature:............................ - 30°C to + 110°C
Ambient temperature: .................................. -20°C to +90°C
Mounting position:...........................................................Any 230 V AC 5/2-way valve
or
Technical data of the 5/2-way valve 24 V DC
Degree of protection acc. to DIN 40050:...................... IP 65
Electrical connection: ...................Socket outlet (DIN 43650)
Power input (AC):.......................................................4.5 VA
Power input (DC): ....................................................... 2.5 W Possibly protective
Duty factor: .................................................................100 % conductor
Compressed-air supply
Fig. 2: Connection diagram
7 Mechanical design
At the 5/2-way valve :
• Supply compressed air to "P"
At the socket outlet of the 5/2-way valve:

• Connect an electrical signal (24 VDC or 230 VAC).
• Connect a protective conductor if necessary.
Fig. 1: Mechanical design
Double-acting, part-turn actuator

Ball valve
Electromagnet with socket outlet (DIN 43650)
5/2-way valve
Compressed-air supply "P"
2 knurled screws for pneumatic throttle
Page 3
10 Start-up
This vendor part is not allowed to be put
into operation until it has been
established that the system in which it is
to be installed complies with the
requirements of the applicable EC
DANGER! directives, harmonized standards,
European standards or equivalent
national standards.
• Actuate the manual release for the 5/2-way valve.

The ball valve opens.
• Set the 5/2-way valve to the OFF position again.
The ball valve closes.
• Adjust the opening and closing speed with the knurled
screws .
S = Knurled screw for adjusting the opening speed
R = Knurled screw for adjusting the closing speed
11 Maintenance during operation

The unit requires no maintenance if it is operated in the
proper way and suitable control media are used.
12 Troubleshooting
Fault Possible Remedy
cause
Valve does not Chips inside valve Clean valve
close fully
Valve does not Compressed-air Check
work supply incorrect compressed-air
supply
Pneumatic Open pneumatic
throttles closed throttles
Page 4

INSTRUCTION MANUAL
DIFFERENTIAL PRESSURE GAUGE
with adjustable contact
Nominal Con- Switching Pressure ID no. ID no.
pressure nection range chamber Connecting cable M12 connector
[bar] [bar]
25 G1/4"u 0 - 6 Aluminium 126.479.5
25 G1/4"u 0 - 1.6 Aluminium 835.291.6
25 G1/4"u -1.0 - 0 Aluminium 836.912.6
25 G1/4"u 0 - 6 VA 1.4305 836.911.8
25 G1/4"u 0 - 1.6 VA 1.4305 835.292.4
40 G1/4"u 0 - 6 VA 1.4305 939.921.3
40 G1/4"u 0 - 1.6 VA 1.4305 939.376.1
25 G1/8"h 0 - 6 Aluminium 938.539.4
25 G1/8"h 0 - 1.6 Aluminium 938.538.6 970.949.4
40 G1/8"h 0 - 6 VA 1.4305 970.829.8
40 G1/8"h 0 - 1.6 VA 1.4305 970.830.6

975.129.8
1 Contents 2.2 Types of identification used in the Instruction
Manual
1 Contents ........................................................................2
2 Safety instructions........................................................2 Danger! Non-observance can result in
2.1 Safety instructions for installation and operating serious or fatal injury!
personnel .......................................................................2 DANGER!
2.2 Types of identification used in the Instruction Manual2
3 General information......................................................2 Warning! Non-observance can lead to
3.1 Manufacturer............................................................2 damage to technical equipment!
3.2 Specifications of the Instruction manual...................2 CAUTION!
4 Intended application .....................................................3 Safety instructions for work on live
equipment! All work must be carried out by a
5 As-delivered condition .................................................3 suitably qualified electrician.
6 Technical data...............................................................3
• Bullet, indicates the order in which actions
7 Storage ..........................................................................3 are to be carried out.
8 Mechanical design ........................................................3
Arrow, indicates the response of operations.
9 Electrical connection....................................................4
10 Start-up ........................................................................4
10.1 Zero correction.......................................................4
10.2 Adjusting the switching point ..................................4 3 General information
11 Maintenance during operation...................................4 3.1 Manufacturer
12 Troubleshooting .........................................................4 MAHLE Filtersysteme GmbH
Schleifbachweg 45
D-74613 Öhringen
Tel.: +49 (0)79 41 67-0
2 Safety instructions Fax.: +49 (0)79 41 67-4 29
2.1 Safety instructions for installation and
operating personnel 3.2 Specifications of the Instruction manual
The operating manual contains the principal safety MAHLE ID No. .................................................... 975.129.8
instructions, which have to be observed during mounting, Date: .................................................................... 10.02.04
operation and maintenance . Revision: ......................................................................... 05
environment and machine resp. plant. In detail the
noncompliance may result in one of the following risks:
Endangering of persons by electrical, mechanical, and
Endangering of the environment by leakage of
dangerous substances.
Before mounting/starting:
• Read operating manual.
• Train mounting and operating personnel sufficiently.
• Ensure, that the responsible personnel understands fully
the contents of the operating manual.
• Make clear decisions about responsibilities and liabilities.
During operation of the unit:
• Keep the operating manual available at the place of use.
• Observe safety instructions.
• Operate plant only in accordance with the power rating
data .
In case of unclarities:
• Contact the manufacturer .
Page 2
Instruction Manual Differential Pressure Gauge, MAHLE Filtersysteme GmbH, 10.02.04, ID No. 975 129 8, Revision 05
4 Intended application 7 Storage
The differential pressure gauge measures the pressure • Always store in the original packing.
difference between the muddy side and the clean side of • Always store in a dry, frost-free room.
the:
• MAHLE automatic filter
• MAHLE metal-edge filter
• MAHLE axial filter
A signal is sent to the appropriate control when an
adjustable switching point is reached. This starts the filter
cleaning process.
This unit is only allowed to be used in 8 Mechanical design

accordance with the operating
conditions specified in the contract
documentation and in the Instruction
Manual. All forms of use which deviate
from or exceed the limits of use
CAUTION! described above are considered to be
contrary to the intended purpose. The
manufacturer shall not be liable for any
0
damage resulting from such use.
PROHIBITED:
• Use in potentially explosive atmospheres,
DANGER! unless explicitly mentioned in the contract
Fig. 1: Mechanical design (View with numbered cable)
documentation.
Numbered signal cable
Indicator for actual differential pressure
5 As-delivered condition
Zero adjustment
The differential pressure gauge is supplied mounted on the Adjusting screw for switching contact
filter or as an additional set1.
Feet (optional)
6 Technical data
Technical data of the pressure gauge
Max. permissible system pressure:.................... 25 / 40 bar2
Max. permissible differential pressure:................ 1.6 / 6 bar2
Switching range: ................................................. 1.6 / 6 bar2
Max.permissible ambient temperature: ........ -10°C to +70°C
Temp. of meas. medium: ...........................................< 70°C
Measuring lead connection: ..................... G 1/4"u / G 1/8"h2
Diaphragm of parts in contact with medium: ................. FPM
Seals............................................................................. FPM
Technical data of the switching contact

Switch type:.................................1-pole changeover contact
Max. switching capacity (250 V AC):............................... 5 A
Max. switching capacity (30 V DC): ............................. 0.4 A
Max. switching capacity (M12): ........................... 4A/50V AC
Degree of protection acc. to DIN 40050:...................... IP 54
Electrical connection: ...............Numbered cable (1 m), fixed
1
The pressure measuring leads are connected in the
factory. The switching signal may need to be connected by
the user.
2
Depending on type (see ID no.)
Page 3
9 Electrical connection 10 Start-up
All electrical installation work must be This vendor part is not allowed to be put
carried out by a SUITABLY QUALIFIED into operation until it has been
ELECTRICIAN in accordance with DIN EN established that the system in which it is
60204-1!
to be installed complies with the
requirements of the applicable EC
DANGER! directives, harmonized standards,
Switch position in depressurized condition European standards or equivalent
national standards.
10.1 Zero correction

The static operating pressure results in a zero offset.
• Apply the static operating pressure to both the
measuring leads.
• Remove the cover.
2 3 1
• Adjust the pointer of the differential pressure indicator
Connecting cable to zero with the zero correcting screw .
• Re-fit the cover.
Fig. 2: Switch diagram
• Remove the pressure from the measuring leads.
Switch position in depressurized condition 10.2 Adjusting the switching point

• Unscrew the plug (PG7 blanking cap) in the cover.
• Turn the adjusting screw to the required value with a
screwdriver (the setting scale corresponds to the
indicator scale).
• Screw the plug back into the cover again.
2 1 4 5
11 Maintenance during operation
M12 connector The unit requires no maintenance if it is operated in the
Fig. 3: Switch diagram M12 proper way.
12 Troubleshooting
Fault Possible Remedy
cause
No signal contact Measuring lead Clean measuring
or contact connections leads
incorrect blocked
Contacts Check contacts
corroded
Signal leads Rewire signal
reversed leads correctly
(NC / NO)
Page 4

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INSTRUCTION MANUAL

Ident-No. of the Instruction Manual:

8 Transport and storage.................................................... 6 During operation of the plant:

Differential pressure (∆p):

Filter cake: 1. II Applies to surface applications

Suspension (raw suspension):

This filter is only allowed to be used in accordance

Fig. 3: Diagram of the main components

Ratchet for manual operation of the filter element

Seaworthy packing is specified in the contract

• INSTALLATION and OPERATION of

7.2 General data

• Check the conductivity between all

Assembly See contract documentation for special types.

Drain Draining height

Fig. 5: Mechanical installation

= Electrical Fig. 8: Time-controlled cleaning

Fig. 7: Electro-pneumatic connections Time-controlled cleaning and draining

9.3.2 Connection to MAHLE control (optional) T1 T2

Fig. 9: Time-controlled cleaning/draining

Differential pressure/time-controlled cleaning

Fig. 11: Differential pressure/time-controlled cleaning

Gear motor cap

Fig. 13: Initial differential pressures

12.2 Prolonged shut-down (> 48 h) Before all maintenance work:

12.3 Emergency shut-down

• The accident prevention regulations

The filter is pressurized!

14.4 Replacing the filter element

To remove the filter element

Fig. 16: Filter insert

14.3 Cleaning the filter

• Take safety precautions appropriate to the hazard poten-

• Clean and oil the seals (and if necessary renew).

Fig. 18: Replacing the scraper

Important when installing the scraper:

Gland Belleville springs (7)

Packing rings (14)

Fig. 20: Stuffing box accessible

To install the stuffing box

The stuffing box requires very little maintenance. Slight

Fig. 21: Spare parts drawing AF 724 (ID no.: 933.183.6)

1 Filterelement See contract doc. 68 Filter element

1 6kt.-Mutter DIN 934 M6 777 219 7 58 Hexagon nut DIN 934 M6

1 Abstreiferhalter 835 160 3 52 Scraper holder

Qty. Part name/DIN designation ID no. Ser.

Ident-No. of the Instruction Manual:

At the socket outlet of the 5/2-way valve:

Fig. 1: Mechanical design

Double-acting, part-turn actuator

• Actuate the manual release for the 5/2-way valve.

11 Maintenance during operation

Ident-No. of the Instruction Manual:

This unit is only allowed to be used in 8 Mechanical design

Technical data of the switching contact

10.1 Zero correction

Switch position in depressurized condition 10.2 Adjusting the switching point

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