DESCRIPTION AND OPERATING INSTRUCTIONS

FOR THE DUPLEX FILTER

2.04.5 DN 25-50

Contents:

1. Type sheet

2. Spare parts drawing and spare parts list

3. Description and Operating Instructions for the duplex filter

4. Description and Operating Instructions for the filter element cleaning

5. Data Sheet for the Differential Pressure Indicator (to order)

6. Spare parts drawing for the Differential Pressure Indicator (to order)
 ERSATZTEILLISTE TYP 2.04.5

SPARE PART LIST LISTE DES PIECES DE RECHANGE

Typenschlüssel:
2.04.5. =Doppelfilter duplex filter Filtre double
G . =Gehäusedurchmesser cabin diameter diamètre du corps
Q . = Filtereinsatzlänge length of the filter element longueur du panier
DN .= Anschlußflansche connection flanges brides désirées

Pos Bezeichnung
. Designation DN 25 St. DN 32 St. DN 40 St. DN 50 St. DN 65 St. DN 80 St.
Nr. Designation
Verschlußschraube
2 screw plug 2000188 2 2000188 2 2000188 2 2000188 2 2000188 2 2000188 2
vis
Dichtung
3 gasket 3270003 2 3270003 2 3270003 2 3270003 2 3270003 2 3270003 2
joint
Verschlußschraube
4 screw plug 2002885 2 2002885 2 2002885 2 2002885 2 2002885 2 2002885 2
vis
Dichtung
5 gasket 3270002 2 3270002 2 3270002 2 3270002 2 3270002 2 3270002 2
joint
Verschlußschraube
6 screw plug 2002885 2 2002885 2 2002885 2 2002885 2 2002885 2 2002885 2
vis
Dichtung
7 gasket 3270002 2 3270002 2 3270002 2 3270002 2 3270002 2 3270002 2
joint
Stiftschraube
10 bolt 2000002 6 2000002 6 2000004 6 2000004 6 2000004 6 2000007 6
vis
Deckel
11 cover Z26002 2 Z26002 2 Z25721 2 Z25721 2 Z25721 2 Z31610 2
couvercle
O-Ring (Viton) 3030742 3030742 3035046 3035046 3035046 3030367
12 O-Ring 2 2 2 2 2 2
O-Ring (Perbunan) 3040102 3040102 3042329 3042329 3042329 3040107
Mutter
13 nut 2100005 6 2100005 6 2100006 6 2100006 6 2100006 6 2100007 8
ecrou
Kugelhahn
16 ball valve G 1/4 1 G 1/4 1 G 1/4 1 G 1/4 1 G 3/8 1 G 3/8 1
vannes à boisseau
spherique
Küken
18 cock Z25998 1 Z25998 1 Z25889 1 Z25735 1 Z31309 1 Z31612 1
vanne à boisseau
O-Ring (Viton) 3030172 3030172 3030466 3031849 3030175 3030075
19 O-Ring 2 2 2 2 2 2
O-Ring (Perbunan) 3040158 3040158 3040501 3040117 3040119 3040121
O-Ring (Viton) 3030174 3030177
19.1 O-Ring ------- ------- ------- ------- 1 1
O-Ring (Perbunan) 3040180 3031277
Sicherungsring
20 circlip ring 2201921 1 2201921 1 2209026 1 2205389 1 2205119 1 2205119 1
circlip exterieune
Hahnschlüssel
21 plug key WN 48.2 1 WN 48.2 1 WN 48.2 1 WN 48.2 1 WN 48.2 1 WN 48.2 1
clef du robinet
Siebeinsatz Fabr.Nr. Fabr.No. Fabr.No. Fabr.Nr. Fabr.No. Fabr.No.
22 siebe element Filtertyp Filtertype Type de Filtertyp Filtertype Type de
élément filtrant Filtre Filtre
 Quad-Ring (Viton) 3534190 3534190 3533821 3533821
23 gasket 2 2 2 2 ------- -------
joint (Perbunan) 3549015 3549015 3546606 3546606
Dichtung
36 gasket 3380136 2 3380136 2 3382898 2 3380037 2 3380040 2 3380041 2
joint
Schraube
37 bolt 2000002 8 2000002 8 2005659 8 2005659 8 2000511 8 2000511 8
vis
Mutter
38 nut 2100005 8 2100005 8 2100006 8 2100006 8 2100007 8 2100007 8
ecrou
DDA Typ Type Type Typ Type Type
65 DPI Druck Pressure Pression Druck Pressure Pression
IPD
Zylinderschraube
70 screw 2000122 2 2000122 2 2000122 2 2000122 2 2000122 2 2000122 2
vis
Mutter
72 nut 2100003 2 2100003 2 2100003 2 2100003 2 2100003 2 2100003 2
ecrou
Federring
73 spring washer 2209799 2 2209799 2 2209799 2 2209799 2 2209799 2 2209799 2
annneau ressant
 Installation and Operating Instructions for the
BOLL-Duplex Filter Type 2.04.5

General:

The switchable duplex filter type 2.04.5 comprises two

filter housings which are connected in parallel through
a two-stage change-over housing. The filter housings
are designed to meet current regulations in respect of
pressure rating. The filter elements are adequately
protected to cope with the differential pressures which
occur in the filter, details of which are given on the
filter mounted instruction plates. These pressures are
1,2 bar for star-form elements and 0,8 bar for basket-
type elements.

Duplex filters are installed in cases where regeneration

of contaminated filter elements must be carried out
without shutting down the equipment or plant.The
change-over housing, which contains a segment-type
rotating valve, allows shock pressure-free change
over, because as one chamber is closed theother
chamber is opened the same amount, in otherwords, both filter chambers can be put into operation
at the same time whenever the need arises (see Picture 2 - Valve Position Indicator). The
undesired closing of both chambers is prevented by a stop, i.e.by the constructional design of the
change-over housing.

Installation:
The filter housings must not be over-stressed when tightening the filter assembly onto its base or
mounting. This also applies to the pipe connections. It is also important to make sure that the
direction of liquid flow through the filter is compatible with the filter elements installed in the filter.
The flow direction is marked on the filter assembly, usually on the flanges.

According to the AD Information Sheets, the filter housings are

only rated for internal overpressure. Additional external forces
and moments at the connection flanges of the filter are to be
avoided (possibly support feed lines).
I. Segment Valve Operation

The segment valve (18) is operated by the lever (21). The lever moves through an
angle of 144ø. The travel stops of the lever are located inside the change-over
housing.
A cam, which is cast integral with the neck of the segment valve extension, moves over
the valve position indicator plate (25) to indicate to the operator the position of the
segment valve (see Picture 2).

1. Changing over filter chambers:

1.1 Slacken the air vent plug (4) of the cleaned filter chamber.
1.2 Turn the lever (21) to move the position indicator cam from position "1" to position "2"
(see Picture 2). In this position the segment valve opens a port to allow liquid to flow in
and fill the cleaned chamber. As soon as the liquid flows free of air bubbles from the vent
plugt (4), close the vent plug.

2. Preparing the Filter for Operation

2.1 Position the lever (21) in the middle position - both filter chambers in operation.
2.2 Open both filter chamber vent plugs.
2.3 Start and slowly run the plant or equipment.
2.4 As soon as liquid flows from the vent plugs free of air bubbles, close the vent plugs.
2.5 Operate the lever to close one of the filter chambers; whilst the other filter chamber
takes over filtration of the liquid, the other (closed) filter chamber remains in reserve
until, due to contamination, the maximum preset differential pressure is reached. At a
differential pressure of 1,2 bar allowed for starform elements or 0,8 bar allowed for
basket-type elements, the reserve or cleaned filter chamber is to be put into operation
as follows:
2.6 Momentarily open the vent plug (4) of the reserve chamber and check to make sure that
this chamber is full.
2.7 Change over the filters as described under paragraph 1.
2.8 Open the vent plug (4) of the closed filter chamber to relieve any pressure in this
chamber. It will now be possible to check whether the segment valve (18) has in fact
closed the inlet port to this chamber.
Note that a complete sealing of a segment type valve is not possible. By opening the
sludge discharge plug (2), any liquid that has leaked passed the segment valve during
cleaning can be drained off.
2.9 Remove the filter cover (11) from the closed (shutoff) filter chamber.
2.10 Open the sludge discharge plug (2) and drain down the liquid until the liquid level is
below the seat of the element. Remove the filter element from the filter housing.
2.11 Clean the filter element (see the Operating Instructions for cleaning the element).
2.12 Replace the cleaned element into the filter housing. Make sure the seal of the element
is not damaged before replacing the element!
2.13 Replace the filter cover (11). The vent plug is
to be left open at this stage. Make sure that the
cover seal (12) and its seat are clean and in a
good condition, if necessary, renew the seal (12).

It is recommended to wet the recess for

the O-ring (12) in the Filter housing with
Vaseline to make it more difficult for the
O-ring to move..

2.14 Move the lever (21) from position "1" to position "2" - the cleaned filter chamber
will now be refilled and vented of air.
2.15 Close the vent plug - the filter chamber is now in an operational-ready condition.

3. Maintenance
Maintenance of the duplex filter extends to an inspection and eventual replacement of
the sealing elements and screens. If the filter assembly shows signs of corrosion, then it
should be reconditioned or renewed as necessary.
The filtering of cooling water and other certain types of operating mediums can lead to
formation of harmful deposits on the surfaces of the components in the change-over
housing, it is therefore advisable to operate the change-over mechanism at regular inter
vals to avoid seizure of the segment valve.

Removing and Replacing the Segment valve (18)

3.1 Open both filter chamber vent plugs (4) to depressurize the filter chambers.
3.2 Drain both filter chambers.
3.3 Using circlip pliers (DIN 5256C - Securing Borings), remove the circlip (20) from the
groove.
3.4 By rotating and at the same time lifting the segment valve (18), remove the valve
from the change-over housing.
3.5 Detach the O-rings (19).
3.6 Thoroughly clean the segment valve and examine the valve for damage. Remove any
traces of scoring by polishing the valve with a suitable, fine carborumdum paste.
Examine the valve bore in the change-over housing and if necessary treat in the
same manner.
3.7 Lightly oil the O-rings (19) and then refit them in the grooves of the segment valve. It is
recommended to renew these O-rings as, due to hardening and compression they
loose a certain amount of elasticity.
3.8 Carefully insert the segment valve (18) into the top of the change-over housing and, by
pressing down and rotating the valve at the same time, push the valve into the housing.

3.9 Position the indicator cam to point to the centre position on the valve position indica tor
plate (see Picture 2).
3.10 Now push the segment valve further down into the bore until the groove for the circlip (20)
becomes visible.
3.11 Refit the circlip (29) in the groove.
3.12 Check the segment valve for ease of operation.
3.13 Prepare the filter assembly for operation as described in paragraph 2.

BOLL & KIRCH assumes no liability for any mistakes by any misuse of the product.
We reserve the right to change this description without any prior notice!
 Cleaning star pleated elements and replacing
disposable cartridges with radial sealing
The filter elements are to be cleaned whenever the admissible differential
pressure has built up (suction filter 0.5 bar; pressure filter 0.8 bar).
With disposable cartridges it is necessary to replace the cartridge at a ∆p of max.
2 bar.

Disposable cartridges are not regenerable!

1. Isolate filter vessel from the liquid circuit (see operating

instructions for simplex or duplex filters).

2. Depressurise the filter vessel by opening the venting plug

and removing the housing cover after undoing the cover
screws.

3. Open the drain in filter bottom and drain liquid.

4. Pull the filter element or disposable cartridge with the handle (124)
out of the housing. Push the handle (124) over the recess in the
filter ring (1). Remove handle to facilitate cleaning.
A magnetic rod (130) can be attached to the filter bracket (124).

When a new star filter is supplied, the filter bracket

(124) must be replaced together with the magnetic
rod (130)

5. Place individual elements in a container with cleaning liquid

"BOLL CLEAN 2000", allow to soak and then force "BOLL
CLEAN 2000" through them from the inside outwards using
a BOLL high-pressure cleaner type 5.04. Then repeat this process
from the outside inwards.

6. Check fabric for clean state and damage by holding the filter element against a light source, e.g. a torch.
Uniform light emission indicates that the fabric is cleaned well; repeat cleaning operation,
if necessary.

7. Check seals (30) and provide them with a thin oil film to facilitate installation. Insert handle (124) back
into the ring (1) and turn.
When replacing the disposable cartridges, it is vital to use the handle (124).
When changing disposable cartridges, make sure that the filter bracket sits correctly.

The handle (124) has to be installed to adjust the filter element or disposable cartridge and is
therefore essential.

8. Bolt housing cover back onto filter vessel and close drain.

9. Fill the filter slowly and do not close vent until liquid emerges (also see operating instructions for simplex or
duplex filters).

BOLL & KIRCH assumes no liability for any mistakes due to misuse of the product.
We reserve the right to change this description without prior notice!
 Fax to: +49 40 656 57 31 or mailto: [email protected]
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Fax to: +49 40 656 57 31 or mailto: [email protected]