Our innovative products are solving complex filtration challenges that improve people's lives, enhance engine and equipment performance and protect our environment. Donaldson has the technical expertise, superior customer support and vast network of locations around the world to meet your toughest filtration needs - from initial system design through replacement products.
Hydraulic Filtration Product Guide
Return Line Filters • Suction Line Filters • In-Line Filters • Service Instructions • Accessories
Donaldson Delivers Performance Under Any Pressure! Clean, dry oil is essential for your equipment.
Donaldson Company, a leader in filtration solutions for 100 years, has proven performance in thousands of applications – offering the industry's largest selection of replacement hydraulic, lube and gear oil filtration products for contamination control.
Distributed by:
Medium and high pressure filters
FCK-LC
p 145
420
FPK03&04 - AP420
p 139
420
FPK02
p 127
420
FPK04 (AP 223-224-225)
p 139
300
FMK-FM
p 105
120
FLK
p 113
40
HMK04 - Duramax
p 119
34,5
FCK-LC
p 109
60
HMK05 - Duramax
p 123
24
Flow (l/min)
350
0
50
100
150
200
250
300
400
450
500
550
600
650
700
750
800
Return line filters
FLK-FLS
p 57
30
FHK-FIR
p 69
10
FBK-FRCA
p 63
10
Combo 200 / 300
p 75
10
Combo 120
p 75
10
FHK-FIR
p 69
10
FIK-FIS
p 51
10
FIK-FIO(T)
p 43
10
Flow (l/min)
350
0
50
100
150
200
250
300
400
450
500
550
600
650
700
750
800
Suction line filters
FLK-FLA
p 93
30
FBK-FACA
p 99
10
PXX-FAL
4
p 89
PXX-FIOA - Sucon Strainer
p 83
NA
Flow (l/min)
350
0
50
100
150
200
250
300
400
450
500
550
600
650
700
750
800
Reference Drawing
Setting (bar)
Protection Class
Part
Kind
Contact
Cable Clamp
Max. Values
Remark
103
with thermostat at min. temperature at 30°C
Normally Open (3) / Closed (2)
PG11 - DIN 43650
30 VAC - 30 VDC; 0,5 A res. and 0,2 A ind.
P171963 Electrical Differential
A
1,4
IP65
Normally Open (3) / Closed (2)
PG11 - DIN 43650
30 VAC - 30 VDC; 0,5 A res. and 0,2 A ind.
P171961 Electrical Differential
A
1,4
IP65
26
18
Normally Closed
6-30 V DC; 0,2 A
P163839 Electrical Differential
B
1,25
P162400 Electrical Differential
B
1,25 Normally Open
6-30 V DC; 0,2 A
Normally Closed
43
20
P763976 Electrical Differential
B
2,75
6-30 V DC; 0,2 A
P763975 Electrical Differential
B
2,75 Normally Open
6-30 V DC; 0,2 A
Normally Closed
P167455 Electrical Differential
B
2,75
6-30 V DC; 0,2 A
P165194 Electrical Differential
B
2,75 Normally Open
6-30 V DC; 0,2 A
P164745 Electrical Differential
B
1,7 Normally Open
6-30 V DC; 0,2 A
PG7 - DIN 46248 PG7 - DIN 46248 PG7 - DIN 46248 PG7 - DIN 46248 PG7 - DIN 46248
48 VAC - 30 VDC; 0,5 A res. and 0,2 A ind. 48 VAC - 30 VDC; 0,5 A res. and 0,2 A ind. 48 VAC - 30 VDC; 0,5 A res. and 0,2 A ind. 48 VAC - 30 VDC; 0,5 A res. and 0,2 A ind. 48 VAC - 30 VDC; 0,5 A res. and 0,2 A ind.
P171967 Electrical
Vacuum C
-0,3 Normally Open IP65
Normally Closed Normally Closed
10
44
P173105 Electrical
Vacuum C
-0,3
IP65
P173104 Electrical Pressure
C
1,2
IP65
P171966 Electrical Pressure
C
1,2 Normally Open IP65
P764431 Electrical Pressure
C
2,5 Normally Open IP65
P162696 Visual
Differential
D
1,7
64
P167580 Visual
Differential
D
3,4
41 54
73
26
P171950 Visual
Differential
E
1,4
9
P171958 Visual
Pressure
F
1,2
P764612 Visual
Pressure
F
2,5
G 1/8
3 color scale; connection central at back
P171954 Visual
Vacuum G -1 till 3
3 color scale; con- nection at the side
P171953 Visual
Vacuum G -1 till 5
9
18
24
Reference Drawing
Setting (bar)
Protection Class
Cable Clamp
Part
Kind
Contact
Max. Values
Remark
P761058 Visual
Differential
H
3
Ø 29
P171945 Visual
Differential
H
5
G 1/2
30
32
201
Normally Closed
Packard Connector
6-30 V DC; 0,1 A
P170926 Electrical Differential
I
2,75
9/16-18UNF
182
41
21
Normally Open
Cannon Connector
P171143 Electrical Differential
J
1,25
6-30 V DC; 0,2 A
with thermostat at min. temperature at 30°C
54
Normally Open (3) / Closed (2)
250 VAC - 30 VDC; 5 A res. and ind.
P171944 Electrical Differential
K
5
IP65
PG11
Normally Open (3) / Closed (2)
250 VAC - 30 VDC; 5 A res. and ind.
P171947 Electrical Differential
K
5
IP65
PG11
G 1/2
Normally Open (3) / Closed (2)
30 VAC - 30 VDC; 0,5 A res. and 0,2 A ind.
54
P761057 Electrical Differential
L
3
IP65
PG11
Normally Open (3) / Closed (2)
30 VAC - 30 VDC; 0,5 A res. and 0,2 A ind.
P761056 Electrical Differential
L
5
IP65
PG11
G 1/2
43
18
106
Normally Open
Packard Connector
P171087 Electrical Differential
M 2,75
6-30 V DC; 0.2 A
P171959 Visual
Vacuum N -0,3
G 1/8
457
35
28
Normally Open (white) or Closed (red)
P173893 Electrical Differential
P
2,75
IP65
3 Wires 6-30 V DC; 0,1 A
9/16-18UNF
57
28
254
Normally Open (white) or Closed (red)
110V AC - 24V DC; 2 A
P173944 Electrical Differential
Q
1,4
IP65
3 Wires
9/16-18UNF
Hydraulic Filtration Product Guide Table of Contents
Hydraulic Accessories T.R.A.P. TM breathers ....................................................... 15 0 Hydraulic Cart for Off-Line Filtration........................ 151 TCO ................................................................................... 15 4 T C A ................................................................................... 15 6 FS ...................................................................................... 157 F F C A ................................................................................. 15 8 LVO/LVOT....................................................................... 159
Introduction Donaldson introduces new product line........................ 6 Overview.............................................................................. 8 Technical References .....................................................13
Return Line Filters Low Pressure Filters in-Tank
F IK- F IO ............................................................................... 3 5 FIK-FIOT ............................................................................43 FIK-FIS ............................................................................... 51
Service Instructions..........161
Low Pressure Filters in-Line FLK-FLS .............................................................................57 FBK-FRCA .........................................................................63 Return &/or Suction Line Filters Low Pressure Filters in-Tank FHK-FIR .............................................................................69 SRK-COMBO ....................................................................75 Suction Line Filters Low Pressure Filters in-Tank FIOA ...................................................................................83 Low Pressure Filters in-Line FAL .....................................................................................89 FLK-FL A............................................................................. 93 FBK-FACA .........................................................................99 Medium Pressure Filters In-Line FMK-FM ..........................................................................105 FCK-LC ............................................................................. 109 FLK.................................................................................... 113 DURAMA X – HMK 04................................................... 119 DURAMA X – HMK 05 ...................................................123 High Pressure Filters In-Line FPK 02 – AP280.............................................................. 127 FPK 02 & 04 – AP220 ....................................................133 FPK 03 & 04 – AP420.....................................................139 FCK-LC .............................................................................145
Conversion Tables .............165
Product Part Index ............187
Hydraulic Filters & Accessories • 5
Donaldson introduces new product line
FLK Medium Pressure Hydraulic Filtration
Engineered Filtration Power Donaldson FLK filtration technology delivers all the latest hydraulic filtration advancements for Original Equipment Manufacturers in a single package. The FLK system, a reusable housing with disposable filter cartridge, can be configured with Donaldson’s advanced Synteq XP ™ media technology – or with other Donaldson media offerings – to satisfy a wide range of performance requirements. Optimum Housing Design FLK assemblies provide high pressure fatigue ratings. This robust, reusable housing and disposable cartridge design creates less waste than standard metal spin-on designs. The versatile FLK filter head also accommodates multiple filter lengths – reducing part numbers stocked while offering greater application coverage. Cleaner, Easier Servicing Industrial, raised hand grips make it easy to remove the housing from the head without the need for special servicing tools. The oil drain port on the bottom of the housing and the locking grab handles on the filter cartridge allow for cleaner servicing. The filter handles lock into place – simplifying positioning during reassembly. Short removal clearance is needed for filter replacement so the assembly can easily fit into tight spaces.
Our FLK hydraulic filtration systems are packed with innovative features that deliver cleaner, error proof filter servicing.
Integrated By-pass Valve
Robust, proven design
RadialSeal ™ Sealing Technology • No metal-to-metal contact – upstream flow • Easy-to-torque, error proof sealing • Robust, reliable seal on upstream side of filter
Unique Head to Cartridge Interface Connection RadialSeal ™ Sealing Technology • No metal-to-metal contact – downstream flow • Robust, reliable seal on clean side of
Anti-dust Seal
Environmental Care Donaldson offers an optional metal-free, high-capacity cartridge that can be easily crushed or fully incinerated.
filter – prevents cross contamination of oil
• Keeps threads free from contamination • Easier to remove and reassemble during service
Filter Cartridge
• Media beading on outside of cartridge supports optimum filtration under high pressure differential • Locking grab handles makes for cleaner servicing and simplifies filter position during servicing Industrial Hand Grips No special servicing tools needed
Synteq XP ™ Media Technology
Delivers high performance – lower pressure drop, superior cold-start filtration and extended filter life Closed End Cap Eliminates the possibility of contamination to clean side of assembly during servicing
Locking Grab Handles Cleaner, easier servicing
Oil Drain Port Oil drain port used to drain oil during servicing
6 • Hydraulic Filters & Accessories
Upstream Flow
Industry Proven Sealing Technology
Downstream Flow
Enhanced Reliability Donaldson pioneered RadialSeal™ sealing technology for air filtration more than 20 years ago. We’ve applied this proven design to hydraulic filtration in order to create a clean, leak-resistant seal – with no metal-to- metal contact for a new standard in system cleanliness.
This improved sealing technique protects systems from harmful ingressed contaminants and also prevents cross contamination of oil. By moving the threads outward, the RadialSeal interface increases the surface area which provides a robust connection with superior vibration resistance, a common challenge in today’s heavy-duty applications. RadialSeal™ Guarantees a Reliable, Sure-Fit Robust seal on the clean side of filter is easy-to-torque and provides error-proof filter servicing. No metal-to-metal contact on both the downstream and upstream sides means no cross contamination of oil.
Industry Shaping Media Technology
Synteq XP™ Media Technology for Optimal Filtration Performance Donaldson’s breakthrough in synthetic filter media technology takes hydraulic filtration performance to a whole new level. This resin-free bonded media provides improved filtration to increase filter dirt holding capacity and reduce pressure drop, resulting in enhanced system performance and protection.
Synteq XP™ Media Synteq XP is thermally bonded together to create small, consistent fibers – increasing the filter capacity. The pores remain unobstructed, resulting in reduced pressure drop and more surface area for capturing and retaining smaller particles. Synteq XP Delivers: • Lower operating pressure drop • Higher efficiency for optimal hydraulic system protection • Superior cold-start filtration • Extended filter life (up to 2 to 3 times that of traditional media)
See brochure No. F111379. For more technical information, consult p. 113.
Hydraulic Filters & Accessories • 7
OVERVIEW
Hydraulic filtration solutions Engineered for today's industrial & mobile equipment
The best solutions for clean, dry oil. Count on Donaldson to have the right filters, contamination control products and services to protect critical components in hundreds of applications – in the factory and on heavy-duty mobile equipment. When you need hydraulic filtration, Donaldson delivers.
Low Pressure Filter
High Pressure Filter
Medium Pressure Filter
Strainer
In-Tank Filter
Breather
Full product range The industry's largest selection of in-stock filters and accessories – manufactured with consistent, high- quality performance.
Expert technical support Prompt, accessible and knowledgeable customer service experts.
High-performance filtration Increase dirt-holding capacity and lower ' P with Donaldson high-performance DT filters.
8 • Hydraulic Filters & Accessories
OVERVIEW
Hydraulic filtration solutions Engineered for today's industrial & mobile equipment
Performance under any pressure • Low, medium and high pressure filtration • Spin-on, cartridge and in-tank style filters
Breather
Low Pressure H y drauli c Filters
High Pressure H y drauli c Filter
In-Tank H y drauli c Filter
Le v el G auge
Pressure G auges
Medium Pressure H y drauli c Filter
Off-line filtration Filter carts, filter panels and Filter Buddy™ handheld filtration.
Water removal Systems and products designed to prevent water ingression and remove entrained water.
Vacuum dehydrators & coalescers Quick removal of free water, dissolved water, particles and gases.
See Catalog No. F112100 ENG
Hydraulic Filters & Accessories • 9
OVERVIEW
Industry shaping technology Global design & logistic capabilities
Donaldson has pioneered the use of a wide range of engineering, design and testing tools used during the product development and validation process.
Engineering capabilities • Design centers in three key regions – Europe, United States and Asia Prediction and simulation • CAD
Test & evaluation tools
Structural Analysis • Per SAE, ISO, and NFPA standards • Burst • Collapse • Pressure impulse and fatigue Tensile compression • Used to test material, component and assembly properties Environmental chambers • Allows testing at hot or cold temperature, with humidity control Flow test benches • Allows measurement of static and dynamic flow and restriction for a device • Allows calculation of device restriction at varying flows and temperatures • System simulation Filtration performance testing • ISO, SAE, NFPA • Customer standards • Contaminant (particle or water) removal efficiency • Contaminant capacity Analytical chemistry laboratory • Optical microscopy • Scanning electron microscopy (SEM) • Chemical analysis
• Media modeling • Fluid mechanics • Structural analysis • Thermal analysis
Development and validation
Filter durability • Filtration performance testing per applicable SAE and ISO standards • Fabrication integrity • Environmental conditions • Salt spray and thermal cycling • Pressure fatigue • Flow fatigue • Hydrostatic burst • Flow benches • Vibration benches • Gravimetric analysis Rapid prototyping • SLA, SLS • Investment casting • RTV molding
• Fourier transform infrared (FTIR) • Gas chromatography (GC/MS) • Thermal analysis (DSC, TGA) • Liquid chromatography
10 • Hydraulic Filters & Accessories
OVERVIEW
Industry shaping technology Global design & logistic capabilities
Design validation • Test cell locations in three key regions – United States, Asia and Europe
Manufacturing Locations for liquid filtration • Europe, United States, Canada, Mexico and Asia-Pacific • Located strategically with global partners Base component materials • Built for long-life, durability, corrosion resistance and liquid compatibility • Metal and non-metal materials • Methods to enhance media durability include oven-curing, wire backing and multiple layered media Packaging options • Returnable packaging • Heavy-duty packaging • Pallets ISPM-15 compliant for international routing Logistics / distribution Donaldson has established a global distribution network to serve our customers locally and around the world. We operate as a global company with a network of primary distribution locations that support a mature hub of regional distribution centers and warehouses. Donaldson distribution centers are strategically located around the globe to quickly and accurately deliver filtration and exhaust products wherever replacement products are needed. We work with a network of transportation, third party logistics companies, consolidators and cross-docking facilities to meet or exceed our customers’ requirements. Customers around the world benefit from our umbrella of distribution centers. We focus our efforts on local support and the capabilities of our staff. We continue to make significant investments in facilities, systems, supply chain relationships and staffing to offer the best order fulfillment options available.
• High viscosity ' P • High temperature • Flow fatigue • Used oil analysis
• Component durability • 24/7 durability testing • Web-based test cell monitoring access • Fluid compatibility
Vibration/shaker • Multiple benches • Performance vibration with flow test • Can apply random, shock or custom variable vibration profiles • Capable of hot or cold tests Field testing • On and off highway • Heavy-duty • Tests conducted on both end user and OEM applications Field data acquisition • Real time measurements • Remote communications • On-line collection tools • Review daily, weekly and monthly reports to analyze operational trends Quality certified • All facilities are ISO/TS certified Quality controls • Consistent, reliable product • On-site verification test units and equipment • Part number specific PLC controls • Manufacturing dates for tracking and warranty
Hydraulic Filters & Accessories • 11
OVERVIEW
Industry shaping technology Donaldson Italy capabilities
Leader in designing and manufacturing liquid filters Donaldson Italia Srl was established in 1992, when DCI bought the existing Italian filter manufacturing company FBO, specialized in hydraulic filtration (industrial & mobile). The company grew during the last 20 years, passing from 50 up to 210 employees. Over the years, Donaldson Italia Srl was and is able to develop new synthetic media, spin-ons and high pressure filters. This mainly thanks to the synergy with DCI and by supplying a huge number of OEM's. One of our main characteristics is the big flexibility and the capacity to develop customized products. As all Donaldson factories, Donaldson Italia srl achieved the quality certification according to ISO 9001/2 and ISO 14000 as well as quality certification of our major OEM customers.
Donaldson Italia Srl in Ostiglia, Mantova (Italy)
Donaldson Italy Srl manufacturing means quality production Most of the filter production process is automated, this enables us to build filters faster and with higher precision.
Daily plant production capacity (10.000m²): • 4.000-8.000 Duramax hydraulic spin-ons
• 3.000-5.000 hydraulic cartridges • 1.000 hydraulic filter assemblies • 4.000 low pressure spin-on filters and liquid filters. Recent investments in a new liquid lab and the engineering and sales office doubled the production facility.
12 • Hydraulic Filters & Accessories
OVERVIEW
Industry shaping technology Mix&Match – your flexible hydraulic solutions
History Mix&Match is introduced to provide you more flexibility and a higher availability of hydraulic products. You can create your own complete filter by selecting separately a housing, a cartridge and an indicator. The majority of these components will be stocked to provide you fast with the products you need.
The idea of Mix&Match
Same cartridge size, different media
One housing for all different efficiencies
How to create your hydraulic product via the catalog? The tables are composed in such a way that all components that fit together are on 1 row. 1. Pick the product series depending from the position in the hydraulic system, the working pressure and the required flow 2. Pick the required element based upon flow and efficiency ?
3. Follow this row to the right and the available (empty) housing is shown 4. Pick the indicator of your choice (make sure that it fits the predrilled hole).
All cartridges are delivered with a sticker, with the Donaldson cartridge spare part number, that will mark the housing from the outside. All complete Mix&Match filters need to have this sticker attached to the outer housing.
Hydraulic Filters & Accessories • 13
OVERVIEW
14 • Hydraulic Filters & Accessories
Technical References Table of Contents
Donaldson provides this technical reference as a short course in “Hydraulic Filtration” – for those who want to gain a better understanding of hydraulic filtration. In industrial and mobile applications at factories all over the world, we too often see hydraulic circuits that don’t include proper fluid filtration, or include it as an afterthought. Good filtration needs to be an integral part of the hydraulic circuit to ensure the long life and proper operation of the pumps, valves and motors. A € 100 l lter protects your € 100,000 equipment. This section is offered to aid in choosing the filter that will help you achieve the ideal cleanliness levels and longest life for your critical components.
Topics
Hydraulic Components Need Protection How Contamination Damages Precision Parts
14 14 14 14 15 16 17 17 18 19 19 20 22 23 23 24 25 26 28 30 31 32 32
Types of Contaminant
Typical Factors in Component Life Where Contamination Comes From
Fluid Conditioning
Proper Filter Application
Fluid Properties
Types of Hydraulic Fluid
How Filter Media Functions in a Filtration System
How Filter Media Collects Particles Basic Types of Hydraulic Filter Media
Symbols Used
Donaldson Filter Media Efficiency Ratings per ISO 16889 Test Standards
ß
Beta Ratio Centistokes
Hydraulic Filtration Pressure Drop
cSt
Four Major Factors Contribute to Pressure Drop
Viscosity/Temperature Chart Filter Design and Construction
DP
Pressure Drop or Differential Pressure International Standards Organization
ISO
Combining the ISO Rating and Filter Performance Ratings
m
Micron or micrometer
Filter Efficiency Standards
ppm SSU SUS
Parts per million
Donaldson Hydraulic Filter Media Beta Ratings
Cleanliness Level Correlation Table
Saybolt Seconds Universal
Compatibility of Donaldson Filter Media with Hydraulic Fluids
Threads
Material in this section is in the public domain, not confidential, and may be copied for educational purposes at any time. Information was collected from many sources, both public and private, including Donaldson Company, Inc. Engineering Departments, Eaton Corporation, the Lightning ® Reference Handbook from Berendsen Fluid Power, Hydraulics & Pneumatics Magazine, National Fluid Power Association (NFPA), and various industry authorities.
Hydraulic Filters & Accessories • 15
TECHNICAL REFERENCE
Hydraulic Components Need Protection
Types of Contaminant • Many different types of contamination may be present in hydraulic fluid, causing various problems. Some are: • Particulate (dust, dirt, sand, rust, fibers, elastomers, paint chips) • Wear metals, silicon, and excessive additives (aluminum, chromium copper, iron, lead, tin, silicon, sodium, zinc, barium, phosphorous) • Water • Sealants (Teflon®* tape, pastes) • Sludge, oxidation, and other corrosion products • Acids and other chemicals • Biological, microbes (in high water based fluids)
Fluid power circuits are designed in all shapes and sizes, both simple and complex in design, and they all need protection from damaging contamination. Abrasive particles enter the system and, if unfiltered, damage sensitive components like pumps, valves and motors. It is the job of the hydraulic filter to remove these particles from the oil flow to help prevent premature component wear and system failure. As the sophistication of hydraulic systems increases, the need for reliable filtration protection becomes ever more critical.
* Te fl on is a registered trademark of E.I.Dupont de Nemours & Co., Inc.
How Contamination Damages Precision Parts
Typical Factors in Component Life Studies show that most (typically 70%) of hydraulic component replacement 70% Surface Degradation
V al v e Bod y
This illustration of a simple hydraulic valve illustrates how particles damage components. In normal operation,
Inlet
S p ool
is necessary because of surface degradation, and most of that is due to mechanical wear. Proper filtration of hydraulic fluids can lengthen component life.
70% mechanical wear from: • abrasion • fatigue • adhesion
O utlet
O utlet
the spool slides back and forth in the valve body, diverting oil to one side of the valve or the other. If a particle lodges between the spool and valve body, it will erode small wear particles from the metal surfaces. As these wear particles are moved back and forth by the action of the spool, they can roll into a burr that jams the spool and disables the valve.
30% corrosion
15% Accidents
15% Obsolescence
Disaster Strikes When filters are not a main component of the hydraulic circuit, disaster awaits. Here, piston rings were eaten away by contaminants.
Component Damage Looking down the barrel of an hydraulic cylinder, we can see the scratches along the inside surface. Don’t cut costs by eliminating hydraulic filters. It could cost you more in the long run in major component repairs.
16 • Hydraulic Filters & Accessories
TECHNICAL REFERENCE
In-Operation The major source of contamination are the pump and actuators, the hydraulic cylinder, or the hydraulic motor. Wear-generated contaminants are a hazard during normal hydraulic system operation. The circuit actually generates additional particles as the fluid comes into contact with the precision machined surfaces of valves, motors and pumps. Contaminant levels can keep doubling with every new particle generated. The result can be catastrophic if these contaminants are not properly filtered out of the system.
Where Contamination Comes From There are a surprising number of contaminated sources in a hydraulic system or circuit. New Hydraulic Fluid Adding new fluid can be a source; even though it’s fresh from the drum, new hydraulic fluid isn’t clean. (It may look clean, but, remember, the human eye can only see a particle the size of about 40 m.) Oil out of shipping containers is usually contaminated to a level above what is acceptable for most hydraulic systems: typically, new fluid has a cleanliness level about the same as ISO Code 23/21/19, and water content is typically 200 to 300 ppm. Never assume your oil is clean until it has been filtered. One very effective way of ensuring thorough fluid conditioning is with a dedicated off-line circulation loop, or “kidney” loop filtration. Built-In Built-in contamination, also called primary contamination, is caused during the manufacture, assembly and testing of hydraulic components. Metal filings, small burrs, pieces of Teflon tape, sand and other contaminants are routinely found in initial clean up filtration of newly manufactured systems. Ingressed Ingressed or external contamination comes from the environment surrounding the system. Dirt can enter the hydraulic fluid supply through leaking seals, reservoir breather caps, and worn cylinder rod seals. Ingressed moisture, particularly, can cause long-term problems. As a hot system cools at night, cool moisture-laden air can be drawn into the reservoir; as the air condenses, water is released into the reservoir. Water in excess of 0.5% by volume in a hydrocarbon-based fluid accelerates the formation of acids, sludge and oxidation that can attack internal components, cause rust, and adversely affect lubrication properties. The severity of ingression and type of contaminant are dictated by the applications and environment. Induced Maintenance procedures can introduce contamination into the system. Opening the system allows airborne particles to enter. Leaving the system open during operation provides continuous ambient particle ingression. Keep your system closed as much as possible.
Load
Motion
Flow
D y nami c Clearan c e (μm)
Chi p / G rit too large to enter c learan c e
Clearan c e Size Parti c les intera c t with surfa c es to c ause abrasi v e wear
Rubber & Elastomers Due to temperature, time, and high-velocity fluid streams, rubber compounds and elastomers degrade – thus releasing particulates into the fluid. This may be from hoses, accumulator bladders, seals, or other elastomer products. High Water Based Fluids The water in HWBF tends to support biological growth and generate organic contamination and microbes. Replacement of Failed Components Failure to thoroughly clean fluid conductor lines after replacing a failed hydraulic pump will cause premature catastrophic failure. Donaldson recommends frequent oil sampling to ensure proper contamination control. Sample test points should be close to hydraulic pumps and at other key locations that provide safe, reliable access to the fluid while under full system pressure.
Hydraulic Filters & Accessories • 17
TECHNICAL REFERENCE
filters or active venting systems usually provide adequate removal means. For large quantities of water, vacuum dehydration, coalescence, and centrifuges are appropriate techniques for its removal. However, as each of these techniques operates on different principles, they have various levels of water removal effectiveness. The chart below provides comparative information on these techniques and their relative effectiveness. Care should be taken to apply the best technique to a given situation and its demands for water removal. Chemical Removal Removal of acids, sludge, gums, varnishes, soaps, oxidation products and other chemicals generally requires an adsorbent (active) filter with Fuller Earth, active type clays, charcoal, or activated alumina. Heat Removal Removing heat is important to maintain viscosity and prevent fluid breakdown. Usually performed with heat exchangers, including air-to-oil and water-to-oil types, finned coolers, or refrigerated units. Heat Addition Added heat is used for cold temp start-up to get fluid viscosities within operational limits. Use heaters, immersion or in-line. Kidney Loop Filtration One very effective way of ensuring thorough fluid conditioning is with a dedicated off-line circulation loop, or “kidney” loop. This system uses a separate circulation pump that runs continuously, circulating and conditioning the fluid. Multiple stages and types of filters can be included in the circuit, as well as heat exchangers and in-line immersion heaters.
Fluid Conditioning Fluid Conditioning is the term for the overall
conditioning of the fluid in the hydraulic system, and encompasses particulate removal via filters along with other various methods for removing silt, air, water, heat,
acid, sludge or chemicals. Particulate Removal
Particulate removal is usually done with mechanical filters. A well designed reservoir that allows settling will also help in keeping particulates out of the mainstream fluid. For ferrous particulates and rust, reservoir magnets or strainer band magnets can also be used. Other methods such as centrifuging or electrostatic filtration units can also be used, particularly in continuous batch processing and fluid reclamation. Removal of Silt Silt, defined as very fine particulate under 5 m in size, requires very fine filtration or “oil polishing.” Air Removal Getting air out of the system is best done by adding 100 mesh screen in the reservoir, approximately 30° from horizontal to coalesce entrained air and allow larger bubbles to rise to the surface when reservoir velocities are low. Water Removal A number of techniques exist to prevent water or moisture ingression or to remove water once it is present in a hydraulic or lube oil system. The best choice of technique for removal is dependent on the whether or not the water exists as a separate phase (dissolved or free), and also on the quantity of water present. For example, the presence of water or moisture can be reduced or prevented from entering a fluid reservoir through the use of absorptive breathers or active venting systems. However once free water is present in small quantities, water absorbing
Water Prevention and Removal Techniques
Prevents Humidity Ingression
Removes Dissolved Water
Removes Free Water
Removes Large Quantities of Free Water
Usage
Limit of Water Removal
Adsorptive Passive Breather
prevention prevention and removal
Y
n/a
Y
Y
Y
down to <10% saturation
Active Venting System
Water Absorbing Cartridge Filter removal
Y Y Y Y
only to 100% saturation only to 100% saturation only to 100% saturation down to ~20% saturation
Centrifuge Coalescer
removal removal removal
Y Y Y
Vacuum Dehydrator
Y
18 • Hydraulic Filters & Accessories
TECHNICAL REFERENCE
Proper Filter Application When selecting a new filter assembly or replacement filter, it’s important to first answer some basic questions about your application. Where will the filter be used? What is the required cleanliness level (ISO code) of your system? What type of oil are you filtering? Are there specific problems that needed to be addressed? It’s also important to think about the viscosity of the fluid in your system. In some machinery lubrication applications, for example, the oil is very thick and has a tougher time passing through the layer of media fibers. Heating techniques and the addition of polymers can make the liquid less viscous and therefore easier to filter. Another option is to install a filter with larger media surface area, such as the Donaldson W041 or HRK10 low pressure filters, that can accommodate more viscous fluids. (see Catalog No. F112100) Next, think about duty cycle and flow issues. Working components such as cylinders often create wide variations in flow – also called pulsating flow – that can be problematic for filters with higher efficiency ratings. On the other hand, dedicated off-line filtration (also called “kidney loop”) produces a very consistent flow, so it makes sense to use a more efficient filter. Filters used in applications with steady, continuous operation at lower pressures will last longer than filters that must endure cycles of high pressure pulsating flow. Generally, the lower the micron rating of a filter, the more often it needs to be changed since it is trapping more particles. Finally, it’s wise to ask yourself, “How much is my equipment worth?” Calculate how much it would cost to replace the equipment in your system, in case of component failure, and make sure those areas are well protected with proper filtration. (For example, high performance servo valves are very sensitive, costly components that need to be protected with finer filtration media.) Minimizing maintenance costs through good contamination control practices requires proper filter application based on the specific contamination problems. Good contamination control means cost-effective filtration. When looking for a filter, first assess the needs of your system and any problem areas.
Characteristics to Consider When Specifying a Filtration System 1. Oil Viscosity 2. Flow 3. Pressure
Fluid Properties Lubricity The property of the fluid that keeps friction low and maintains an adequate film between moving parts. Viscosity The thickness of the fluid as measured by resistance to flow. The fluid must be thin enough to flow freely, heavy enough to prevent wear and leakage. Hydraulic fluids thicken when they cool and thin out as they heat up. Because some hydraulic systems work under wide temperature extremes, viscosity can be an important factor. Viscosity Index (VI) The rate of viscosity change with temperature: the higher the index, the more stable the viscosity as temperature varies. VI can sometimes be improved by additives, usually polymers. Rust Resistance Rust inhibiting chemicals in hydraulic fluids help overcome the effects of moisture from condensation. Oxidation Resistance Oxidation inhibitors delay the sludgy/acidic effects of air, heat, and contamination in the system. Foaming Resistance Although control of foaming depends largely on reservoir design, anti-foaming additives in the fluid also help. 4. What Components will be protected by the filter 5. Cleanliness level required (expressed in ISO code 6. Type of oil/fluid 7. Environment (the system, the surrounding conditions, etc.) 8. Duty cycle 9. Operating Temperature
Hydraulic Filters & Accessories • 19
TECHNICAL REFERENCE
HFD Fluids The HFD group is a classification giben to several different types of synthetic products that do not contain petroleum oil or water. Phosphate ester fluids were the first HFD fluids and are the most fire resistant within the HFD family. Not as popular today, their use declined due to poor environmental performance, limited compatibility, and high cost. Certain phosphate esters have very high auto-ignition temperatures and are still used in specific applications, such as aircraft and power generation. A common brand is known as Skydrol® (registered trademark of Solution, Inc.). Skydrol requires EPR seal for chemical compatibility. Today most phosphate esters have been replaced by polyol esters. Based on organic esters, polyol esters are the most common HFD fluids used today. They offer good inherent fire resistance, good compatibility with system materials, excellent hydraulic fluid performance, and easy conversion from petroleum oil. In addition, the organic nature of these fluids gives them good environmental performance in biodegradability and aquatic toxicity. Another type of synthetic, fire resistant fluids have been formulated for certain niche markets. Water free polyalkylene glycols (PAGs) feature extended fluid life and good environmental performance. Technically an HFD fluid, PAGs (also known as polyalphaolefins (PAOs) are more often used for their biodegradability and overall environmental friendliness. This group also contains the synthetic silicone (siloxane) oils, known for their anti- foaming properties. Biodegradable With increasing concern about the environmental impact of hydraulic system leaks and spills, biodegradable fluids are receiving expanded usage, particularly in Europe. There are two types of common biodegradable hydraulic fluids: 1) vegetable-based oils, such as sunflower or rapeseed oils, and 2) synthetic oils like diesters, etc. Generally, systems using biodegradable fluids are derated for maximum and minimum temperatures. Users who replace standard hydraulic oils with biodegradable oils must check with filtration component manufacturers to confirm that the fluid and components are compatible.
Types of Hydraulic Fluid There are many kinds of fluids used for power, but they can basically be called petroleum-based fluids, biodegradable fluids, and fire-resistant fluids. A brief description of some of the types in each category are listed below; for details on these or others, consult your filter supplier or refer to a reputable manual on hydraulics, such as the Lightning Reference Handbook, published by Berendsen Fluid Power, Whittier, CA 90601. Petroleum Based (Hydrocarbon) These are the most commonly used fluids in hydraulic systems. Their major advantages are low cost, good lubricity, relatively low/non-toxicity, and common availability. This type of fluid is not just plain oil; rather, it is a special formulation with additives that make it suitable for hydraulic systems. Mostly, the additives inhibit or prevent rust, oxidation, foam and wear. Variations: • Straight oils: same as petroleum-based oil but without the additives. • Automatic transmission fluids (ATF): excellent low temp viscosity and very high VI. • Military hydraulic fluids (ie: MIL-H-5606 and MIL-H-83282): also called ‘red oil’ because of the color. Low viscosity, good for cold temp operations, but may have to be modified for pumps. Fire Resistant Fluids There are two types of fire-resistant fluids commonly used in hydraulic applications: Phosphate Esters and High Water Based Fluids (HWBF). Although generally not as viscous at cold temperatures as petroleum-based fluids, they are fire resistant due to their high content of noncombustible material. Very useful in overcoming the likelihood of fire caused by a broken hydraulic line spraying petroleum fluid into a pit of molten metal, onto a hot manifold, into a heat-treating furnace, or other ignition source. Some types of HWBF: • Oil-in-water emulsions (HFA): typically 95% water and 5% oil, with the oil droplets dispersed throughout the water. Provide some fire resistance, but due to oil content, other fluids are superior. • Water-in-oil emulsions (invert emulsion HFB): typically 40% water and 60% oil, with the water dispersed in the oil. Provide some fire resistance, but due to oil content, other fluids are superior. • Water-glycol (HFC): typically 40% water and 60% glycol. Excellent fire resistance. Since glycol is an antifreeze, water- glycol can be used at lower temps. NOTE: HWBF may require reduced pressure rating of pumps and other components .
20 • Hydraulic Filters & Accessories
TECHNICAL REFERENCE
How Filter Media Functions in a Filtration System
How Filter Media Collects Particles There are four basic ways media captures particles The first, called inertia , works on large, heavy particles suspended in the flow stream. These particles are heavier than the fluid surrounding them. As the fluid changes direction to enter the fiber space, the particle continues in a straight line and collides with the media fibers where it is trapped and held.
The job of the media is to capture particles and allow the fluid to flow through. For fluid to pass through, the media must have holes or channels to direct the fluid flow and allow it to pass. That’s why filter media is a porous mat of fibers that alters the fluid flow stream by causing fluid to twist, turn and accelerate during passage.
Inertial Impaction
Flow
Flow
Parti c le
Media Fiber
The second way media can capture particles is by diffusion . Diffusion works on the smallest particles. Small particles are not held in place
Fiber La y ers
The fluid changes direction as it comes into contact with the media fibers, as illustrated above. As the fluid flows through the media, it changes direction continuously as it works its way through the maze of media fibers. As it works its way through the depths of the layers of fibers, the fluid becomes cleaner and cleaner. Generally, the thicker the media, the greater the dirt-holding capacity it has.
by the viscous fluid and diffuse within the flow stream. As the particles traverse the flow stream, they collide with the fiber and are collected.
Parti c le
Diffusion
Flow
Media Fiber
Looking at a cross-section view of the fibers, we can see how the flowstream is accelerated as it flows into the spaces between the fibers.
The third method of particle entrapment is call interception . Direct interception works on particles in the mid-range size that are not quite large enough to have inertia and not small enough to diffuse within the flow stream. These mid-sized particles follow the flow stream as it bends through the fiber spaces. Particles are
Fiber La y er
Flow
Parti c le
Interception
Flow
Media Fiber
intercepted or captured when they touch a fiber. The fourth method of capture is called sieving and is the most common mechanism in
Media Fiber
Parti c le
hydraulic filtration. As shown at right, this is when the particle is too large to fit between the fiber spaces.
Sieving
Flow
Media Fiber
Parti c le
Media Fiber
Hydraulic Filters & Accessories • 21
TECHNICAL REFERENCE
Basic Types of Hydraulic Filter Media Filter Media Media is a term used to describe any material used to filter particles out of a fluid flow stream. There are four basic types used to remove contamination in hydraulic applications:
Cellulose Media (Traditional)
HOW IT WORKS
Cellulose fibers are actually wood fibers, microscopic in size and held together by resin. Fibers are irregular in both shape and size. Cellulose often has lower beta ratings, which means there are smaller pores in the media. Smaller media pores cause more flow resistance, resulting higher pressure drop. While cellulose provides effective filtration for a wide variety of petroleum-base fluids, in certain applications it results in poor filtration performance as compared to synthetic media. c
SEM 100X
SEM 600X
MEDIA IMAGE
Synteq™ Media (Full Synthetic)
Synthetic fibers are man-made, smooth, rounded and provide the least resistance to flow. Their consistent shape allows for control of the fiber size and distribution pattern throughout the media mat to create the smoothest, least inhibited fluid flow. Consistency of fiber shape allows the maximum amount of contaminant-catching surface area and specific pore size control. The result is media with predictable filtration efficiencies removing specified contaminants and maximum dirt holding capacity. The low resistance of synthetic media to fluid flow makes it ideal for use with synthetic fluids, water glycols, water/oil emulsions, HWCF and petroleum-based fluids.
HOW IT WORKS
SEM 100X
SEM 600X
MEDIA IMAGE
22 • Hydraulic Filters & Accessories
TECHNICAL REFERENCE
Wire-Mesh Media
Wire-mesh media consists of stainless steel, epoxy-coated wire mesh available in 3 mesh sizes:
HOW IT WORKS
• 100 mesh yields 150 m filtration • 200 mesh yields 74 m filtration • 325 mesh yields 44 m filtration
Typically wire-mesh filters will be applied to catch very large, harsh particulate that would rip up a normal filter. You may also find this media useful as a coarse filter in viscous fluid applications.
SEM 60X
SEM 100X
MEDIA IMAGE
Water absorption media quickly and effectively removes free water from hydraulic systems. Using super-absorbent polymer technology with a high affinity for water absorption, this media alleviates many of the problems associated with water contamination found in petroleum-based fluids. Water Absorbing Media
HOW IT WORKS
SEM 100X
SEM 600X
MEDIA IMAGE
Hydraulic Filters & Accessories • 23
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