T 20 Series Racor 500FG Turbine
User Manual: T-20 Series
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500FG Turbine Series Fuel Filter/Water Separator Instruction Part Number 15332 Rev E The Racor 500FG Turbine Series fuel filter/water separator protects the precision components of your engine from dirt, rust, algae, asphaltines, varnishes and especially water, which is prevalent in low distillate fuels. Contaminants are removed from fuel using the legendary three stage process described below. Contact Information How It Works Parker Hannifin Corporation Racor Division P.O. Box 3208 3400 Finch Road Modesto, CA 95353 phone 800 344 3286 209 521 7860 fax 209 529 3278 racor@parker.com www.racorcustomers.com www.parker.com/racor Stage 1 - Separation Stage 3 - Filtration Using the fuel flow, the stationary turbine separates large solids and free water through enchanced centrifugal force. Engines will benefit from near 100% water separation and fuel filtration with Racor’s proprietary Aquabloc® water repelling media. The replaceable filters are available in 2, 10, and 30 micron ratings. Stage 2 - Coalescing Smaller water droplets and solids coalesce on the conical baffle and fall to the collection bowl. Mounting Instructions 500FG (Front) 4.0 in. (10.2 cm) 4.5 in. (11.4 cm) 3/8 in. (1.0 cm) diameter clearance for fasteners V 7.5 in. (19.1 cm) Install 500FG Assembly within 10º of verticle ± 10º Installation Diagram Optional Bypass Installation and Operation (allows user to service filter without shutting down engine.) Valves 1 2 3 Unit On-line Open Open Closed Unit Off-line Closed Closed Open Pressure Side: Fuel transfer pump not to exceed maximum PSI or flow rate of filter. Not ideal - pumps emulsify water hindering filter performance. Suction (vacuum) Side: Primary (first) filter - use 30 micron. If it is the only filter in the system, use 2 or 10 micron. Fuel tanks above filter head pressure should not exceed maximum PSI of filter. Fuel Tank (Pressure Side Installation) Install a shut-off valve when fuel tank is higher than filter Engine Valve 2 Valve 1 Fuel Tank (Ideal Vacuum Side Installation) Install a check valve (with light or no restriction) when tank is lower than filter to maintain prime. Fuel transfer pump (IDEAL vacuum side installation) Valve 3 Maintain a clearance of at least 5 in. (12.7 cm) above and at least 2 in. (5.1 cm) below filter assembly to service unit and drain bowl. Fuel Tank (Vacuum Side Installation) Fuel tank below filter Do not exceed 5’ (1.5m) of lift or 4 inches of mercury (inHg) of inlet piping restrictions Installation Guidelines These customer supplied materials should be on hand before beginning installation. • Shop Towels • Mounting Hardware • Inlet/Outlet Fittings • Fuel Hose • Clean Diesel Fuel • Parker Super O-lube or Clean Motor Oil • Thread Sealant (no thread tapes) Positioning filter assembly: Filter assemblies should be installed on vacuum side of fuel transfer pump for optimum water separating efficiency. See Installation Diagram. Keep fuel line restrictions to a minimum. Locate the 500FG filter assembly between horizontal planes of bottom of fuel tank and inlet of fuel pump, if possible. If 500FG filter assembly is installed in an application where the fuel tank is higher than filter, a shut-off valve must be installed between the tank and 500FG filter assembly INLET. This will be used when servicing the replacement filter. Before installing filter assembly: • Obtain good ventilation and lighting. • Maintain a safe working environment. • Engine must be off for installation. • DO NOT smoke or allow open flames near installation. Installing filter assembly: Completely remove any vacuum side filters in fuel line between fuel tank and fuel pump. This is where the Racor filter will mount. Leaving these filters in place will add to fuel line restriction. Filter heads cast into engine or that are non-removable or hard piped should be serviced with a new filter and left in place. Keep fuel flow restriction to a minimum. Always use the maximum size fuel hose possible. Do not make sharp bends with flexible hose as kinks may occur. Avoid use of two 45° elbow fittings where one 90° elbow will work. Service Draining Water: Frequency of water draining is determined by contamination level of fuel. Inspect or drain collection bowl of water daily or as necessary. Collection bowl must be drained before contaminants reach top of turbine or when Water Detection Module (optional) indicates it’s time to drain water. Vacuum Applications / Installations: When routing hose, avoid surfaces that move, have sharp edges, or get hot (such as exhaust piping). 1. Close inlet valve (or valve #1) and open drain on bottom of bowl with a suitable container in place. Priming The Unit 2. Close drain after all water and contaminants have been evacuated – DO NOT leave drain open too long as it will eventually completely drain entire filter assembly of water AND fuel. 1. Remove T-handle and lid from top of filter assembly. 2. Fill filter assembly with clean fuel. 3. Lubricate lid gasket and T-handle O-ring with clean fuel or motor oil. 4. Replace lid and T-handle, tighten snuggly by hand only – do not use tools. 5. If applicable, refer to equipment operator’s manual to complete fuel priming procedure. 6. Start engine, check for fuel system leaks. Correct as necessary with engine off and pressure relieved from filter assembly. 3. Follow Priming Instructions. Pressure Applications / Installations: 1. Open drain on bottom of bowl to evacuate water and contaminants with a suitable collection container in place. Head pressure will push any water and contaminants out of drain while keeping filter primed. 2. Close drain after all water and contaminants have been evacuated – DO NOT leave drain open too long as it will eventually completely drain entire filter assembly of water AND fuel, and possibly drain entire tank. Filter Replacement Frequency of filter replacement is determined by contamination level of fuel. Replace filter every 10,000 miles (16,000 km), every 500 hours, every other oil change, when vacuum gauge (optional) reads between 7 to 10 inches of mercury (inHg), if power loss is noticed, or annually, whichever comes first. Note – always carry extra replacement filters as one tankful of excessively dirty fuel can plug a filter. Use only genuine Racor Aquabloc® replacement filters – see Replacement Part List All Applications: 1. Bypass filter assembly with bypass valves, if applicable. 2. Remove T-handle and lid. 3. Remove filters by holding bail handles and slowly pulling upward with a twisting motion. Dispose properly according to local regulations. diesel fuel before installation. 5. Refer to Priming Instructions, otherwise, fill unit with clean fuel, replace lid and T-handle and tighten snuggly by hand only – do not use tools. Note - above ground tanks or transfer pump applications may use head pressure to prime filter assembly. 4. Remove and discard old lid gasket and T-handle O-ring and clean seal glands of any dirt or debris. Lubricate new gasket and seal (supplied with new filter) with motor oil or Troubleshooting Procedures A major cause of power loss or hard starting is result of an air leak (or clogged filter). If your unit will not prime or fails to hold prime, check that drain, bowl and filter are properly tightened. Next, check all fitting connections and ensure fuel lines are not pinched or clogged with contaminants. If problems persist (and filter is new) call Racor Technical Support for assistance: (800) 344-3286 or (209) 575-7555. Specifications 500FG Maximum Flow Rate: Port Size 60 GPH (227 LPH) 3/4´´-16 UNF (SAE J1926) Service Clearance Above Assembly Below Assembly 5.0 in. (12.7 cm) 2.0 in. (5.1 cm) Replacement Filters 2 micron 10 micron 30 micron 2010SM-OR 2010TM-OR 2010PM-OR Water In Bowl Capacity 3.7 oz. (109 ml) Height 11.5 in. (29.2 cm) Width 5.8 in. (14.7 cm) Depth 4.8 in. (12.2 cm) Weight (dry) Max. Working Pressure Clean Pressure Drop Water Removal Efficiency Ambient Temp. Range Max. Fuel Temperature 4.0 lb (1.8 kg) 25 PSI (1.7 bar) 0.25 PSI (1.7 kPa) 99% -40°F to +250°F (-40°C to +121°C) 190°F (88°C) Parts and kits listed can be purchased from a Racor distributor. Go to www.racorcustomers.com for a distributor near you. Part Number Description 1 RK 11888 T-handle and O-ring Kit (9/16”-18 UNF Threads) Hand Tighten 1a 11350 T-handle O-ring 2 RK 15078 (FG) Lid Kit 2a 15005 Lid Seal B 2010SM-OR (2 micron), 2010TM-OR (10 micron), or 2010PM-OR (30 micron) Replacement Filter (All Models) RK 15383-01 Heater Kit (12 vdc, 300 watt) RK 15383-02 Heater Kit (24 vdc, 300 watt) 3 RK 15081 Bowl Fasteners (4) Tighten to 60 in. lbs (6.78 Nm) 4 RK 15035 (FG) Bowl Ring Kit 5 RK15405 (FG >2002) RK 15279-01 (FG <2002) Clear Bowl Kit (includes 5, 5a, 9, 9a, 11, & 11a) Clear Bowl Kit (includes 5*, 5a, 11, & 11a) 5a 15374 Bowl Seal 6 RK 15013D Turbine Centrifuge and Conical Baffle Kit Hand Tighten 7 (not sold seperately) Check Ball Seal 8 RK 15010B Check Ball Kit (includes 7) 9 RK 30476 (FG >2002) Self-venting Drain Kit Tighten to 30 in. lbs (3.39 Nm) 9a (not sold seperately) Drain Gasket RK 21067 Heater Feedthru Kit Tighten to 15 in. lbs (1.69 Nm) RK 11-1679 Feed-thru Plug Kit Tighten to 15 in. lbs (1.69 Nm) 43506 Feedthru or plug O-ring RK 21069 Water Probe Kit Tighten to 15 in. lbs (1.69 Nm) C 10 10a 11 RK 20126 (FG) Bowl Plug Kit Tighten to 15 in. lbs (1.69 Nm) 11a (not sold seperately) Water Probe or Plug O-ring 12 RK 11780 (FG <1993) Drain Assembly Kit 12a 12b 12c (not sold seperately) (not sold seperately) (not sold seperately) Drain Seal (Finger) Drain Body O-ring Drain O-ring 13 RK 30488 (FG 1994-2002) Drain Assembly 9a 12b (not sold seperately) (not sold seperately) Drain Gasket Drain Body O-ring RK 15378 (FG) Clamp Bracket Kit RK 11838 Carraige Bolt Kit (not sold seperately) 500 Body/Housing D E 1 1a 2 2a B 10 C 10a D E 7 8 6 5a 5 11 9 4 3 11a 9a Drain Configurations RK 11780 Drain Kit (1993 & Older) RK 30488 Drain Kit (1994-2002) RK 30476 Drain Kit (2002-Current) 5* 5* 5 11a 11 11a 11a 11 11 12a 12b 9a 12b 9a 9 13 12 12c T-handle Vacuum Gauge The T-handle vacuum gauge monitors your filters condition. As your filter slowly becomes clogged with contaminates, restriction (resistance to flow) increases. Because of this restriction, more air is mixed with fuel and less fuel is delivered to the engine (fuel degassing). This will result in loss of power and eventually stall the engine. Installing a T-handle vacuum gauge in your fuel system gives you a visual monitor of your filter condition. Excessive resistance on the gauge means it’s time to change the filter. Specifications RK 11-1969 Application For 500 Filter Assemblies Thread Size 1/4˝ NPT bottom boss mount Fitting Thread Dimensions 9/16˝-18 UNF 2.0˝ Diameter x 1.1˝ Depth Weight (dry) Ambient Temperature Range 0.3 lb (0.1 kg) -40 to +250 oF (-40 o to +121 oC) o Special Notes: For severe vibration applications, mount gauge on a stable, remote location and connect to the source using flexible tubing. After September 1999, Racor converted many liquidfilled gauges to new silicone dampened movement. This new (dry) technology provides a vibration resistant design that never leaks fluid or requires adjustments due to temperature or altitude variations. Limited Warranties Statement All products manufactured or distributed by Racor are subject to the following, and only the following, LIMITED EXPRESS WARRANTIES, and no others: For a period of one (1) year from and after the date of purchase of a new Racor product, Racor warrants and guarantees only to the original purchaser-user that such a product shall be free from defects of materials and workmanship in the manufacturing process. The warranty period for pumps and motors is specifically limited to ninety (90) days from date of purchase. A product claimed to be defective must be returned to the place of purchase. Racor, at its sole option, shall replace the defective product with a comparable new product or repair the defective product. This express warranty shall be inapplicable to any product not properly installed and properly used by the purchaser-user or to any product damaged or impaired by external forces. THIS IS THE EXTENT OF WARRANTIES AVAILABLE ON THIS PRODUCT. RACOR SHALL HAVE NO LIABILITY WHATSOEVER FOR CONSEQUENTIAL DAMAGES © Parker Hannifin Corporation FLOWING FROM THE USE OF ANY DEFECTIVE PRODUCT OR BY REASON OF THE FAILURE OF ANY PRODUCT. RACOR SPECIFICALLY DISAVOWS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED INCLUDING, WITHOUT LIMITATION, ALL WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE (EXCEPT FOR THOSE WHICH APPLY TO PRODUCT OR PART THEREOF THAT IS USED OR BOUGHT FOR USE PRIMARILY FOR PERSONAL, FAMILY, OR HOUSEHOLD PURPOSES), WARRANTIES OF DESCRIPTION, WARRANTIES OF MERCHANTABILITY, TRADE USAGE OR WARRANTIES OR TRADE USAGE. Warning Failure or improper selection or improper use of the products and/or systems described herein or related items can cause death, personal injury and property damage. This document and other information from Parker Hannifin Corporation, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the applications are met. The products described herein, including with limitation, product features, specifications, designs, availability and pricing, are subject to change by Parker Hannifin Corporation and its subsidiaries at any time without notice. The following statement is required pursuant to proposition 65, applicable in the State of California: ‘This product may contain a chemical known to the State of California to cause cancer or reproductive toxicity’. July 2010
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