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DEFINITION OF FILTRATION The process by which solid particles are separated from a fluid by passing the fluid through a permeable material that will not let the solid particles through. THE NEED FOR FILTRATION IN HYDRAULIC SYSTEMS The higher pressures and faster cycle times, and the more consistent performance requirements in hydraulic circuits, have resulted in many high precision components being used in pumps, motors, control valves and actuators. Contamination can increase wear on these components, or cause them to jam or malfunction. To keep circuits operating for long periods and avoid costly down time, it is important to ensure that contamination is removed from the hydraulic fluid as efficiently as possible. The cleaner the fluid, the longer life system components will have, and the greater will be the period between breakdowns. HOW FILTERS WORK Oil containing contaminants enters via the inlet port, and flows around the outside of the filter element. As the oil passes through the filter element from the outside to the inside, particles of contaminant are trapped in the filter media. The cleaned oil flows through to the centre tube of the filter element and into the outlet port of the filter. Spin On Canisters and Cartridge type filter elements both work in the same manner.
SPIN ON FILTER
The following electron microscope photographs show the trapping of contaminants in the layers of the filter media.
Dirty 10 micron filter Filter magnified 250 times FILTERS AND ACCESSORIES
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QUALITY
Introduction to Filtration
WHAT IS A MICRON?
1 micron = 1 millionth of a metre 1 micron = 1 thousandth of a millimetre 1 micron = 39 millionths of an inch 25.4 microns = 1 thousandth of an inch (.001) m
10
25
40
70
100
m
Magnified 250 times PRESSURE DROP The understanding of how pressure drop increases as the filter element traps more contaminant influences two important aspects of filter selection. The first is the selection of BYPASS VALVES and the second is the selection of the SIZE OF FILTER. When the filter element is clean, there is a small pressure drop as the oil finds its way through the numerous microscopic passages in the filter element. As the filter element traps more and more contaminant, more and more of the microscopic passages become blocked, increasing the flow rate through the remaining passages, thereby increasing the pressure drop across the filter element. Eventually, if the filter element is not changed, all the passages will become blocked (also known as plugged or clogged); and very little oil will be able to flow through the filter element. The system may stop working due to oil starvation or the filter may collapse or rupture. BYPASS VALVES In addition to the pressure drop due to contamination loading, other factors can increase the pressure drop across the filter element. These include increased viscosity of oil due to contamination, degradation or cold temperatures; and increased flow rates from system components, for example large cylinders retracting quickly can easily double the normal flow rate of a system. To keep the system operating and guard against element collapse or rupture due to any of these factors, many filters incorporate a BYPASS VALVE. The Bypass Valve opens when the pressure drop increases past a predetermined value, to allow flow of unfiltered oil to bypass the filter element. Normally a Bypass Valve is a spring-loaded poppet set to crack open when the pressure drop reaches the predetermined value. It can be located in the filter head or in the filter element.
Many Return Line Filters have Bypass Valves with 0,7 or 1,0 Bar (10 or 14.5 PSI) cracking pressure, and many Suction Line Filters to have Bypass Valves with 0,2 Bar (2.9 PSI) cracking pressure. Suction Line Filters require a lower Bypass Valve cracking pressure than Return Line Filters, to guard against the pump cavitation that may occur with a higher pressure drop. The flow rate for a filter used in a Suction Line application is lower than a similar filter in a Return Line application.
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Technical
Filters
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Intro
A micron (m) is one millionth of a metre, or 0.000039 inches. As a comparison, a grain of table salt is about 100 microns, human hair is 70 microns, 40 microns is the smallest object able to be seen by unaided vision, talcum powder is 10 microns, red blood cells are 8 microns and bacteria are 1 to 2 microns.
It can be seen that pressure drop increases with flow rate. Nominal Flow Rates are published as a guide to the selection of a filter, based on these graphs, calculated as follows: RETURN LINE FILTERS WITH BYPASS VALVE CRACKING PRESSURE OF 1,0 BAR (14.5 PSI): (includes the following Series: RIF-R06, RIF-R10, RIF-RV12, RIF-RP12, RIF-RC12, RIF-FA9, RIF-FA10, RHF-R, RTI-R, RFI-R, RCF-R). The Nominal Flow Rates specified will cause a pressure drop across a clean filter element of 0,5 Bar (7.3 PSI) with 30 centistokes viscosity oil. The filter element life will depend on the amount of contaminant trapped. Nominal flow rate conditions give rise to a Bypass Valve Cracking Pressure to Clean Element Pressure Drop ratio of approximately 2:1. 1,0 Bar (14.5 PSI) pressure drop is effectively the end of the life of the filter element because at that point the Bypass Valve cracks opens and the filter stops filtering. Filter elements must be changed prior to the pressure drop reaching Bypass Valve cracking pressure. RETURN LINE FILTERS WITH BYPASS VALVE CRACKING PRESSURE OF 0,6 TO 0,7 BAR (8.7 TO 10 PSI): (includes RIF14-1, RIF-FA35). The Nominal Flow Rate specified will cause a pressure drop across a clean filter element of 0,3 Bar (4.4 PSI) with 30 centistokes viscosity oil. The filter element life will depend on the amount of contaminant trapped. Nominal flow rate conditions give rise to a Bypass Valve Cracking Pressure to Clean Element Pressure Drop ratio of approximately 2:1. Filter elements must be changed prior to the pressure drop reaching Bypass Valve cracking pressure. SUCTION LINE FILTERS WITH BYPASS VALVE CRACKING PRESSURE OF 0,2 BAR (2.9 PSI): (includes the following Series: RIF-S06, RIF-S10, RIF-SV12, RIF-SP12, RIF-SC12, RHF-S, RCF-S). The Nominal Flow Rate specified will cause a pressure drop across a clean filter element of 0,03 Bar (0.5 PSI) with 30 centistokes viscosity oil. The filter element must be changed before the pressure drop increases to the Bypass Valve cracking pressure of 0,2 Bar (2.9 PSI) and the filter stops filtering. FILTERS WITHOUT BYPASS VALVE: RIF15, RIF-FA8 and RIF-FA39 filters are designed for petrol, kerosene, and diesel fuel filtration. They do not have a Bypass Valve fitted, and flow will stop when the filter element becomes clogged. Filter elements must be changed prior to becoming clogged. FILTERS WITH BLOCKED BYPASS VALVE: (includes the following Series: RIF-B06, RIF-B10, RIF-BV12, RIF-BP12, RIF-BC12, RHF-B). Filters with Blocked Bypass are available for hydraulic oil filtration special applications. Actual flow rates for Blocked Bypass are dependent on system design. Filter elements must be changed prior to becoming clogged. WARNINGS: 1. The above information is only an aid for filter selection. Other factors may affect the performance of a filter. The system designer must consider all criteria when designing a system and ensure that these criteria are satisfied. 2. Nominal Flow Rate information for each filter Series in the Specification tables, and in the Pressure Drop Flow Graphs on pages 304 and 305, relate to oil of 30 centistokes viscosity. The actual flow rate will vary if the oil is of different viscosity. See pages 308 and 309 for information on Effect of Temperature and Viscosity on Flow Rate. 3. See pages 306 and 307 for more information on Warnings and for Filter Selection Guidelines.
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BETA RATIO
1.01 1.5 2 5 10
EFFICIENCY
1% 33.3% 50% 80% 90% 98.7% 99% 99.5% 99.9%
PART NO
RIF-E0610
MULTIPASS TEST RESULTS TO ISO 4572 MICRON 3 6 10 15 20 25 RATING BETA RATING BETA RATING BETA RATIO BETA RATIO BETA RATING BETA RATIO NOMINAL EFFICIENCY% EFFICIENCY% EFFICIENCY% EFFICIENCY% EFFICIENCY% EFFICIENCY%
3
2
50.00%
5
80.00%
75 98.70%
>8000 99.99%
>9000 99.99%
50.00% RIF-E1010 10 3
2
50.00%
5
80.00%
75 98.70% 2
RIF-E1025
25
10 50.00%
3
66.67%
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RIF-E0625
20
10
10
75
Filters
Accessories
This table shows some BETA ratios and the equivalent efficiency.
20
95%
Adaptors
Couplings
Hose
Intro
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Use RIF14-1 curve for RIF15 with petrol and diesel fuel. RIF-FA9, RIF-FA10, RIF-FA35 curve is for 30 cSt oil.
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Intro
SOME OF THE MANY FACTORS TO CONSIDER WHEN CHOOSING FILTERS FOR MINERAL OIL BASED HYDRAULIC FLUIDS ARE: 1. Required cleanliness level. Manufacturers of the various hydraulic system components can advise the oil cleanliness level required to ensure that the component functions correctly. Appropriate micron rating filters should be chosen. Efficiency and capacity must be balanced. The system designer must select a filter that can remove a given percentage of contaminant particles over a particular size with sufficient contaminant holding capacity, so that it can protect the circuit over a reasonable service life. 2. Flow rate of the system. It is important to choose a filter that has a sufficient flow rate. Remember to allow for flow increases due to actuator movement. In some systems the rapid retraction of a cylinder can cause a flow rate from two to five times the normal pump flow rate. If this has not been allowed for, the sudden increase in the flow rate can cause the Bypass Valve to open and allow unfiltered oil through, or may result in filter collapse or rupture. 3. System Operating Pressure and Temperature. Filters must be able to operate at the design pressure and temperature of the circuit. 4. Viscosity of the oil. Pressure Drop charts in this catalogue assume viscosity of 30 centistokes. If the oil is of different viscosity, or if the viscosity of the oil is likely to change due to cold starts, the nominal flow rates should have a correction factor applied to avoid Bypass Valve opening. See pages 308 and 309.
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Suction Strainers Maximum line velocity: 1.5 metres per second (5 feet per second). Maximum pressure drop: 1 (25mm) Hg / 0,03 Bar / 0.44 PSI Diffusers Using tank diffusers helps to prevent air becoming entrapped in hydraulic oil. Air sucked into a pump with the hydraulic fluid can cause cavitation at the pump. Damage to the pump and other components in a system may result. Diffusers and suction strainers perform best when mounted in the bottom third of the reservoir. They should also face in opposite directions, or can be separated from one another by baffle plates to allow the oil to settle, cool and de aerate. Clogging Indicators RYCO recommend the fitting of Clogging Indicators (see page 292) to filters wherever possible. Clogging Indicators provide visual indication of the restriction across the filter element. Filter elements must be changed before the filter Bypass Valve opens and allows unfiltered oil through the filter. If a Clogging Indicator is not fitted, filter elements must be changed on a regular basis so that they do not become plugged. Air Breathers Breather filtration should match the required hydraulic fluid filtration level. Breathers should be replaced regularly, to ensure that they do not become clogged. Pressurised filler breather caps can be used in conjunction with a fully sealed reservoir to increase oil supply to the pump inlet. Pressurised filler breather caps function best on reservoirs that have a fairly constant fluid level. Generally, the more pressure a pump has at the inlet, the quieter it will operate. Reservoirs Oil reservoirs must be fully sealed to prevent contaminants being sucked into the reservoir as the oil level changes. Air should only enter and leave the reservoir via filtered air breathers. QUALITY FILTERS AND ACCESSORIES
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Filters
Accessories
Suction Line Filters Maximum line velocity: 1.5 metres per second (5 feet per second). Maximum pressure drop: no more than 50% of the maximum allowable vacuum recommended by the pump manufacturer. Suction Line Filters should not be used if the pump manufacturer recommends against their use. Closed loop systems are recommended. If possible, use a sealed reservoir and a pressurised breather. WARNING: Do not use Suction Filters with cellulose filter elements where water contamination is possible.
Adaptors
Return Line Filters Return Line filters must be located as close to the Reservoir as possible. Maximum line velocity: 4.5 metres per second (15 feet per second). Maximum pressure drop: no more than 50% of the filter by pass valve setting at normal operating temperature with a clean filter element. Maximum pressure drop of 50% of the filter Bypass Valve setting is the normal recommendation. Using a factor lower than 50% of the filter Bypass Valve setting results in lower flow rates than those at 50%. However the life of the element is increased due to the increased amount of contaminant able to be held before the pressure drop causes the Bypass Valve to open.
Couplings
The following information is provided to aid in the selection of appropriate filtration and reservoir accessories. The system designer must consider all operating parameters and operating conditions when choosing filters and reservoir accessories, and be sure that the selected system provides for those parameters and conditions.
Hose
Intro
( (
)X )X
(These formulae will give an approximate result, but due to the usual conditions of turbulent flow in the housing and laminar flow through the filtration media; the result is not precise. Refer to RYCO Technical Department if precise calculations are required. Also, if extremes of temperature are expected, for example extremely cold starts, these should be allowed for in the selection of the filter.) EXAMPLE ISO 68 oil is used in a system that normally operates at 65C. What is the estimated flow capacity of an RIF-R1025 filter (for maximum 0,5 Bar (7.3 PSI) pressure drop across clean element)? From page 309 graph, ISO 68 at 65C (149F) will be approximately 24 centistokes. Nominal flow rate for RIF-R1025 from Specification table on page 279 or graph on page 304 is 135 litres per minute (for maximum 0,5 Bar (7.3 PSI) pressure drop across clean element). Estimated flow capacity for ISO 68 oil at 65C (149F) for RIF-R1025 = 135 X 30 = 169 litres per minute. 24
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IS O
68
IS O
10 0
15 0
IS O
32
IS O
46
IS O
15
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Accessories
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IS O
22
Hose
IS O
Intro
If gasket dimensions and gasket sealing surfaces are compatible, the ability to use various Spin On Filter canisters on a particular filter head depends on the post thread of the filter head, and the thread of the canister. This Cross Reference Information is presented as a general guide to the RYCO Spin On Filter that can replace another manufacturer's Spin On Filter when installed on that other manufacturer's filter head, for hydraulic filtration applications; based on: 1. Reasonable matching of filtration ratings 2. General dimensions 3. Threads of the canister and of the post of the filter head. 4. Gasket compatibility. The listings do not imply identical dimensions and identical performance. Prior to using products from different manufacturers, users must consider all criteria and satisfy themselves that the products will perform satisfactorily in their particular application. There are many variables to be considered; including, but not limited to, the following: Maximum Working Pressure and Vacuum ratings vary between manufacturers. Nominal Flow Rates and Clean Element Pressure Drops vary between manufacturers. Filtration ratings and efficiencies vary between manufacturers. Temperature ratings and fluid compatibilities vary between manufacturers. Replacing a NOMINAL Rated canister with an alternate NOMINAL Rated canister of the same micron size; and an ABSOLUTE Rated canister with an alternate ABSOLUTE Rated canister of the same micron size; will result in similar but not necessarily identical performance. Replacing a NOMINAL Rated canister with an ABSOLUTE Rated canister of the same micron size is not recommended, because it may result in a Nominal Flow Rate reduction, or increased Clean Element Pressure Drop. Replacing an ABSOLUTE Rated canister with a NOMINAL Rated canister of the same micron size is not recommended, because the level of filtration will not be as fine. Refer to pages 276 to 309 for Technical and other information about Pressure Drop, Warnings and Filter Selection Guidelines, and Effect of Temperature and Viscosity on Flow Rate and Pressure Drop on RYCO products. Due care has been taken in compiling the Cross Reference Information on page 311, but no liability of any kind whatsoever is accepted by RYCO Hydraulics Pty Ltd for any loss damage or loss sustained or incurred by the purchaser or any other party in consequence of or resulting by the use of this information.
The tables below show the ABSOLUTE and NOMINAL filtration ratings for each RYCO canister. BSPP Threaded Canisters last 2 digits of RYCO Part Number are the ABSOLUTE rating
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RIF-EA12GW
Rating 10 nom 10 nom 25 abs 25 nom 10 nom 25 abs 25 nom Rating 10 nom 10 nom
RIF-EA12GM
Thread BSPP UNF UNF UNF UNF UNF UNF Thread BSPP BSPP Gasket
Fairey Arlon/Stauff
SFC5710E FA35-10 FA35-CC25 FA35-25 RIF-EA12GM FA57-10 FA57-CC25 RIF-EA12GM FA57-25 Gasket Filpro SOE5-10 SOE10-10
Check Check Gasket LHA SPE-16-10 SPE-52-10 SPE-15-10 SPE-15-25 SPE-50-10 SPE-50-25 Prince / Cross Rating 10 nom 10 nom 10 nom 25 nom 10 nom 25 nom Rating Thread BSPP BSPP UNF UNF UNF UNF Thread Gasket
Abs Nom Thread OMT 10 3 BSPP 20 10 BSPP CS05AN 10 3 BSPP 25 10 BSPP CS10AN 25 10 UNF 32 25 UNF 27 10 UNF 36 25 UNF Abs Nom Thread Parker UCC 10 3 BSPP MXR.8550 20 10 BSPP MX.1518.4 10x4 10 3 BSPP MXR.9550 25 10 BSPP MX.1591.4. 10x4 25 10 UNF 32 25 UNF 27 10 UNF 36 25 UNF
Rating
Check Check
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Technical
RIF-E0610 RIF-E0625
Filters
Accessories
Abs Nom Thread Hydac 20 10 BSPP 0080MG010P 25 10 BSPP 0160MG010P 25 10 UNF 0080MA010P 32 25 UNF 0080MA025P 27 10 UNF 0160MA010P 36 25 UNF 0160MA025P
Adaptors
Couplings
Hose
Intro
IMPORTANT FITTING INSTRUCTIONS FOR RYCO RIF SERIES SPIN ON CANISTERS 1. Turn off the system and relieve pressure to the filter. 2. Clean the outside of the filter head and the spin on canister. 3. Unthread the old canister and remove it. Arrange a suitable catch pan for any oil that may be released. 4. Clean the gasket contact area on the filter head. 5. Remove the new canister from its protective packaging. Apply a film of oil to the face of the gasket of the new spin on canister, where it contacts the filter head. This is to ensure that friction or twisting during installation does not damage the gasket. IMPORTANT NOTE re RIF-EA1210 and RIF-EA1225 SPIN ON CANISTERS. Two gaskets are supplied. Only one is to be used. See page 277. The wide (stepped) gasket is used with RYCO and other filter heads with wide groove. The narrow gasket is used on filter heads with narrow groove. The gasket used must be a tight fit in the filter head groove. Use of incorrect gasket prevents seal. Refer to RYCO Hydraulics Technical Department if in doubt. After choosing the correct gasket, apply a film of oil to all surfaces of the gasket and install it in the filter head groove. 6. Line up the threads on the canister and the filter post carefully, and spin on the new canister until the gasket contacts the mounting pad on the filter head. (In some systems it may be desirable to place clean oil in the canister, before it is installed, to reduce air inclusion into the system.) 7. Tighten the canister an additional 1/2 to 3/4 turn by hand-do not over tighten. 8. Operate the system and check to ensure there are no leaks. Check oil level and top up if necessary. IMPORTANT FITTING INSTRUCTIONS FOR RYCO CARTRIDGE STYLE FILTER ELEMENTS USED IN RYCO SERIES RHF, RTI, RFI, AND RCF FILTERS 1. Turn off the system and relieve pressure to the filter. 2. Clean the outside of the filter housing around the Top Cover Plate (or around the Bowl to Head join of RHF Series). 3. For RHF-10 and RHF-20 Series, remove the Drain Plug at the bottom of the bowl. Arrange a suitable catch pan for the oil that will be released. Replace the Drain Plug. 4. For RTI, RFI, and RCF Series, remove the bolts holding the Top Cover Plate. For RHF Series, remove the bolts holding the bowl to the head. 5. Remove the old filter element. 149 Micron Stainless Steel mesh filter elements may be cleaned and reused, if there is no damage. 6. Carefully clean inside the filter housing to remove any dirt or sludge. Wipe away from the outlet port. Clean the magnet on the bottom of Top Cover Plates of RTI, RFI and RCF Series filters. 7. Inspect all O Rings, seals and bolts for damage. Replace if necessary. 8. Place the new or cleaned filter element into the filter housing, taking care to ensure it is centrally located, and the O Ring sealing the filter element to the housing is correctly seated. (In some systems it may be desirable to place clean oil in the filter, before it is reassembled, to reduce air inclusion into the system.) 9. Replace the Top Cover Plate or the Bowl while maintaining correct spring location and spring pressure on the filter element. 10. Replace the bolts and tighten in a diagonal order. Check that the two components seat uniformly. 11. Operate the system and check to ensure there are no leaks. Check oil level and top up if necessary.
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