DESCRIPTION AND OPERATING INSTRUCTIONS
FOR BACK-FLUSHING FILTER TYPE 6.46
Order No.
LIST OF CONTENTS
1. Type sheet
2. General notes on the automatic filter
3. Installation of the filter
4. Commissioning
5. Filtration phase
6. Back-flushing phase
7. Functioning of the overflow valves
8. Maintenance
9. Filter candle inspection and cleaning
10. Technical information BOLL CLEAN 2000
11. Sources of faults and their remedy
12. Spare parts drawing for type 6.46
13. Spare parts list for type 6.46
14. Type sheet differential pressure contact indicator
15. Spare parts drawing for the differential pressure indicator
BOLL & KIRCH assumes no liability for any mistakes by improper use of the product.
We reserve the right to change this description without prior notice!
2. General notes on the automatic filter
The back-flushing Filter type 6.46 satisfies the safety standard
for ships' main propulsion units. It is registered by GL, LRS
and other ship classification bodies.
The back-flushing filter type 6.46 is suitable for filtering oils with a viscosity of max.
50 cSt. and an operating pressure of min. 3 bar to max. 10 bar.
The filter works with permanent back-flushing using its own process fluid; the back-
flushed fluid is fed back into the circulation tank or the oil trough again.
No external power is required to operate the automatic filter.
The function of the automatic filter is to protect the bearings, journals and shafts in
the engine from noxious impurities in the oil.
Treating the lubricating oil, i.e. removing the solids discharge, is carried out by a
separator, a centrifuge, a bypass filter or the attached flushing oil treatment unit.
The filter can be mounted both vertically and horizontally directly on the engine or
on the base frame.
In order to satisfy the different requirements of the engine manufacturers, the filter
type 6.46 can be combined with a wide variety of engine attachments.
The filter type 6.46 mainly consists of the following:
- the housing with the inlet and outlet flanges
- the filter element with the appropriate number of filter candles, depending on the
nominal width
- the excess pressure safety devices
- the downstream second filter stage [protective filter (8)]
- the entire flushing facility
- the gear unit including drive turbine.
3. Installation of the filter
Care must be taken during installation of the filter to ensure that clean pipes are
connected to the filter inlet and the filter outlet without any strain.
The inlet and outlet of the filter are marked.
The flushing oil line is to be at least as large as specified in the information sheet.
This line is to be laid without any shut-off device but with a gradient and vented to
prevent any build-up in the pipe.
The potential-free contacts of the differential pressure indicator (24) installed (see
"Differential pressure indicator, section 14) must be wired to monitor the degree of
contamination of the filter elements (7) and the protective filter (8).
The filter housings are only designed for internal overpressure in
accordance with the AD Information Sheets. Additional external
forces and moments at the filter connection flanges are to be
avoided (possibly by supporting the supply lines).
When installing the filters, make sure that any oil or fuel which
leaks due to improper handling cannot result in a fire or injury.
4. Commissioning
4.1 Check to see whether all connections have been made properly.
4.2 Check to see whether the ball cocks in the control line to the differential pressure
indicator are open.
4.3 The following must be observed before switching on the pump:
- Close shut-off device in the bypass line
- Open shut-off device at the filter outlet
- Only partially open the shut-off device at the filter inlet and, after switching on
the pump (to prevent pressure surges), slowly open it fully.
4.4 If the pressure downstream of the filter is less than 2 bar, the shut-off device
downstream of the filter is to be regulated until the appropriate operating pressure
has built up.
4.5 The rotary motion of the flushing facility can now be seen at the visible shaft end in
the filter cover.
If there is an inadmissible rise in the differential pressure during
commissioning (with new plants poss. greater initial
contamination) in spite of perfect back-flushing, a signal is
emitted via the differential pressure indicator. The Filter must be
taken out of service (open the bypass line and close the shut-off
devices on the Filter). Dismantle the Filter element completely
and clean the Filter candles individually (oberserve section 9
"Filter candle inspection and cleaning").
5. Filtration phase
(see drawing Z106374 sheet 1 or Z101308 sheet 1 )
The fluid to be filtered passes through the inlet flange and turbine (14) to the bottom
end of the filter candles (7); a partial stream of about 50% is passed through the
central connection tube (4) to the top end of the filter candles (7). This means that
the fluid flows through the filter candles (7) at both ends from the inside outwards
and most of the dirt particles are retained in the inside of the filter candles (7).
The fluid filtered in this way now passes through the protective filter (8) to the filter
outlet.
6. Back-flushing phase
(see drawing Z106374 sheet 2 or Z101308 sheet 2)
The back-flushing filter type 6.46 operates as a continuous flushing filter and
does not require any external power to drive the back-flushing facility.
The flow energy drives the turbine (14) installed in the inlet flange. The high speed
of the turbine (14) is reduced by the worm gear unit (13) and gear (15) to the lower
speed required for turning the flushing arm (3).
The individual filter candles (7) are now connected successively to the atmosphere
by means of the continuously rotating flushing arm (3), the flushing bush (17) and
nozzle (21).
The pressure gradient thus produced (operating pressure to atmosphere)
results in an extremely efficient cleaning action.
The unfiltered fluid passes through the optimally designed bores of the top cover
plate (9) into the individual filter candles (7) from above. The resultant turbulent
stream in the longitudinal direction of the filter candles (7) (cross-flow back-flushing)
and the counter-flow back-flushing through the filter candles (7) result in a
particularly effective and lasting back-flushing action.
Counter flow back-flushing:
The lower pressure in the interior of the filter candles (7) during
the back-flushing operation (connected with the atmosphere)
and the higher pressure (operating pressure) outside the filter
candles (7) produce a counter-flow through the mesh from the
clean filter side through the dirty filter side to the atmosphere.
This newly developed cross-flow back-flushing feature in conjunction with
the time-tested counter-flow back-flushing principle means that the pressure
drop at the filter remains constant for a longer period.
7. Functioning of the overflow valves
(see drawing Z106374 sheet 3 or Z101308 sheet 3)
Should for any reason the filter candles (7) (first filter stage) no longer be
adequately cleaned, the overflow valves (19) are opened at a differential pressure
of 2 bar upwards and some of the fluid is filtered through the protective filter (8)
(second filter stage).
However, before this situation arises, the installed differential pressure indicator
(24) emits a differential pressure warning (first contact). The cause must now be
localised and remedied.
If this warning is not heeded, an alarm is emitted by the second contact of the
differential pressure indicator (24).
The filter may only be operated in this emergency condition for a
short time (opened overflow valves and differential pressure
warning). Prolonged operation in this mode can result in
damage to downstream components.
The overflow valves are closed under normal operating conditions, even
during start-up at lower fluid temperatures.
8. Maintenance
Section 9 - Filter candle inspection and cleaning - must also be observed.
Even with automatic filters inspections and maintenance must be performed at
regular intervals.
It is extremely important to remember that in spite of constant back-flushing the
mesh may become clogged over the course of time, depending on the quality of the
fluid and whether a bypass treatment unit installed.
In order to maintain trouble-free operation, the following aspects are to be observed
during maintenance:
8.1 The filter must be switched off for all maintenance work.
8.2 Check filter and connections for leaks.
8.3 Conduct visual inspection of all filter candles (7) once a year.
Should a higher differential pressure occur beforehand, all the
filter candles (7) and the protective filter (8) must be checked
and, if necessary, cleaned.
Observe section 9 "filter candle inspection and cleaning".
A highly contaminated protective filter (8) is a sign of
prolonged operation with defective or clogged filter candles (7)
and thus (from a differential pressure of 2 bar upwards)
opened overflow valves (19).
It is imperative to check these components.
8.4 Check the ease of movement of the worm gear unit (13), the turbine (14)
including gear (15) with flushing arm (3).
To this end the cover (34) or the screw plug (34) must be removed. Now check
the ease of movement with a suitable spanner (on the hexagon of the worm
gear unit).
If movement is sluggish, refer to section "Sources of faults and their remedy".
8.5 Replace the dyn. loaded seals (66) as and when required.
It is advisable to replace all static seals during an overhaul.
9. Filter candle inspection and cleaning
(see drawing Z106374 sheet 2 or Z101308 sheet 2)
9.1 Open bypass line.
9.2 Close shut-off devices at the filter inlet and outlet.
9.3 Now drain the filter from the drain screw.
9.4 Pull the entire filter element incl. flushing arm (3) and gear (15) out of the
housing.
Make sure that the exposed gear (15) is not damaged.
9.5 Remove the upper cover plate (9).
9.6 The filter candles (7) can now be pushed out from below or pulled out from
above.
9.7 Place the filter candles (7) in the cold cleaner BOLL CLEAN 2000, max.
soaking time 24 hours.
9.8 After immersing the filter candles (7), clean them from the outside inwards
using high pressure.
It must be ensured that the filter candles are cleaned at a
pressure of max. 60 bar and at a minimum distance of the
cleaning nozzle of 20 cm. Otherwise, damage to the mesh is
possible.
In our experience it is only possible to achieve an almost 100
% cleaning effect by hand with the high-pressure cleaning unit
type 5.04 using BOLL CLEAN 2000.
Refer to the separate description "Filter cleaning unit type
5.04".
9.9 If operating an engine on heavy fuel
If operating on heavy fuel, the filter elements must be checked
after 2 years at the latest and any damaged ones must be
replaced.
We recommend the general replacement of all filter elements
after 4 years.
If operating an engine on diesel oil
If operating on diesel oil, the filter elements must be checked
after 4 years at the latest and any damaged ones must be
replaced.
We recommend the general replacement of all filter elements
after 6 years.
Defective filter candles (7) must not be used again.
Before installation of the entire filter element, the ease of motion
of the flushing facility must be checked.
The flushing arm (3) must not grind against the bottom filter
plate (5).
9.10 Now push the entire filter element into the housing.
By slightly turning the flushing shaft (10), the gear (15) is forced into the drive
pinion of the gear unit (13).
Now re-assemble the filter in the reverse sequence to that described
under points 9.1 - 9.9.
10. Technical information BOLL CLEAN 2000
Solvent-free cold cleaner
Product description
BOLL CLEAN 2000 is a liquid cleaning and degreasing agent for a wide range of
applications. It can be used for virtually all cleaning and degreasing work.
BOLL CLEAN 2000 is miscible with any water - even sea water.
BOLL CLEAN 2000 cleans quickly and thoroughly and is extremely economical.
Even mixed with water in concentration ranges of 1:50, it exhibits good cleaning and
degreasing properties. When BOLL CLEAN 2000 is used, no safety precautions are
needed. BOLL CLEAN 2000 exhibits these outstanding properties without having
the disadvantages of solvent cleaners.
BOLL CLEAN 2000 is non-flammable
does not need to be identified
does not have a pungent smell
is a non-irritant
is physiologically safe
is biodegradable
Federal Office of the Environment Reg. No. 04860019
BOLL CLEAN 2000 can become cold or hot during storage but can be readily used
again at normal temperature.
Field of application
BOLL CLEAN 2000 is suitable for cleaning and degreasing all metals, plastics,
highly adhesive paints etc. It removes oil, wax, grease, rust and numerous other
kinds of dirt.
BOLL CLEAN 2000 is used, for example, in the automobile, engine, aviation, oil (for
drilling equipment), food and drinks, and metalworking industries, in overhauling
and machine workshops, shipping, diesel and electric locomotives, and in electricity
works for cleaning the generators.
Mesh contaminated with heavy oil
Filters contaminated with heavy oil must be soaked in a commercially available
solvent. After being soaked, the filters are cleaned in the BOLL & KIRCH cleaning
unit type 5.04 with BOLL CLEAN 2000 and a high-pressure pump.
Instructions for use
The use of BOLL CLEAN 2000 does not involve any specific cleaning method.
BOLL CLEAN 2000 can be employed in an immersion bath, in a spraying plant, in a
steam jet cleaner or using a manual application process with a cloth, brush or
sponge, depending on the circumstances.
It can be used either cold or warm.
BOLL CLEAN 2000 is miscible with water - even sea water.
Concentration for cleaning mesh: 1:2.5
Temperature: up to max. 60°C
The concentration depends on the type and thickness of the adhering material to be
removed. When used in a concentration of 1:30 and more, rinsing is not necessary.
No visible film remains on the surface.
11. Sources of faults and their remedy
Fault Cause Reasons and remedy
Viscosity too high Wait for normal operating conditions
High volume of dirt Check bypass treatment unit for
operability
Filter candles clogged Clean candles
Flushing volume too low Check flow control device in outlet
and sludge discharge line for
clogging
Shaft end does not turn Turbine jammed
Remove parts jammed between
turbine and wall
∆p rises — Gear unit defective
Check for ease of movement
(as per section 8 "Maintenance")
Replace gear unit if necessary
Flushing arm (3) jammed, Remove
any foreign matter
Operating pressure < 2 bar
Run for prolonged period at higher
pressure 5-6 bar and thus eliminate
the blockage
Oil quantity too low / Increase oil
quantity
DOCUMENTATION PARTS LIST Date 09.11.05
Page 1
Document Description
0639919 backflushing filter
6.46 DN100
Material EN-JS1030
EN-GJS-400-15
EN 1563
Assembly Z42558
Dimension drawing Z101080 Bl.1
max. allowable pressure : 10 bar
max. allowable temperature : 100°C
Test pressure : 1,5 x Calculation pressure
------------------------------------------------------------------------------------
Item ID no. Description Qty Unit
------------------------------------------------------------------------------------
00001 6537802 housing 1 pcs.
00002 6330214 cover 1 pcs.
00003 6552600 flushing arm 1 pcs.
00003 2007222 screwed sealing plug 2 pcs.
00004 5151253 connecting pipe 1 pcs.
00005 5250045 sieve plate bottom 1 pcs.
00006 5250046 sieve plate top 1 pcs.
00007 1360014 Filter Element 78 pcs.
00008 5709912 safety sieve 1 pcs.
00008 7108805 perforated plate cutting 1 pcs.
00009 5110057 covering plate 1 pcs.
00010 5309685 flushing arm shaft 1 pcs.
00011 6853849 turbine housing 1 pcs.
00012 5301235 flange fastening 1 pcs.
00013 2709131 worm gearing 1 pcs.
00014 2784402 turbine wing with wheel hub 1 pcs.
00015 2705519 toothed wheel 1 pcs.
00016 5300723 mounting bushing 1 pcs.
00017 5060722 flushing bush 1 pcs.
00018 0209130 excess current valve 6 pcs.
00021 5003166 nozzle 1 pcs.
00022 2310058 pressure spring 1 pcs.
00023 2703599 deep groove ball bearing 2 pcs.
00024 9902572 differential pressure indicator acc. t 1 pcs.
00025 2000257 slotted cheese head screw 1 pcs.
00026 2301130 grooved pin 1 pcs.
00027 2300010 Spring Type Straight Pin 3 pcs.
00028 2560063 angle ball valve 2 pcs.
00029 2806480 square counter flange 2 pcs.
00030 2009088 stud bolt 8 pcs.
00031 2100007 hexagon nut 8 pcs.
00032 2009088 stud bolt 8 pcs.
00033 2100007 hexagon nut 8 pcs.
00034 6402865 cover 1 pcs.
00035 2000187 screwed sealing plug 5 pcs.
00036 2000155 hexagon socket head cap screw 4 pcs.
00037 2000142 hexagon socket head cap screw 6 pcs.
00038 2000130 hexagon socket head cap screw 3 pcs.
00039 2000130 hexagon socket head cap screw 3 pcs.
................................................................................
DOCUMENTATION PARTS LIST Date 09.11.05
Page 2
0639919 backflushing filter
6.46 DN100
------------------------------------------------------------------------------------
Item ID no. Description Qty Unit
------------------------------------------------------------------------------------
00040 2000197 hexagon socket head cap screw 1 pcs.
00041 2003658 stud bolt 1 pcs.
00042 2000122 hexagon socket head cap screw 2 pcs.
00043 2000154 hexagon socket head cap screw 4 pcs.
00044 2000121 hexagon socket head cap screw 2 pcs.
00045 2000121 hexagon socket head cap screw 3 pcs.
00046 2200235 spring ring 3 pcs.
00047 5008712 disc 1 pcs.
00048 2200007 disc 1 pcs.
00049 2200050 disc 4 pcs.
00050 2008438 hexagon screw 4 pcs.
00051 6024502 bottom fastening 1 pcs.
00052 5708316 mounting sheet 1 pcs.
00053 2000122 hexagon socket head cap screw 2 pcs.
00054 2100003 hexagon nut 2 pcs.
00055 2500024 screwing 2 pcs.
00056 2500025 screwing 2 pcs.
00057 7300002 precision tube nbk 1 pcs.
1.000mm
00060 3040136 o-ring 1 pcs.
00061 3040018 o-ring 1 pcs.
00062 3041700 o-ring 2 pcs.
00063 3030012 Gasket 156 pcs.
00064 3040115 o-ring 1 pcs.
00065 3031743 o-ring 1 pcs.
00066 3040115 o-ring 1 pcs.
00067 3382321 high pressure gasket 2 pcs.
00068 3041106 o-ring 1 pcs.
00069 3270002 gasket 5 pcs.
00070 3332814 flat gasket 1 pcs.
00071 3048235 o-ring 1 pcs.
00075 2209799 spring ring 3 pcs.
00076 2000122 hexagon socket head cap screw 3 pcs.
00077 2100047 hexagon nut 1 pcs.
00079 2000115 hexagon socket head cap screw 1 pcs.
00080 9400997 label: "on / off" 1 pcs.
00080 9407569 label: "in / out" 1 pcs.
00080 9402913 type plate 1 pcs.
00081 3529686 indication bush 1 pcs.
00082 5209684 Tension Ring 1 pcs.
00083 4707080 inspection glas 1 pcs.
00085 2311117 shaft spring 1 pcs.
Überarbeitet am : 17.09.04
Überarbeitet von : Bogda
