Sotras Manual

FILTERS & PRODUCTS FORCOMPRESSORS, VACUUM PUMPS

AND COMPRESSED AIR

S O T R A S

PRODUCT QUALITY SUPPORTEDBY EFFICIENT SERVICE...

Sotras is well established in the filtration industry as one of the leadersin its field, offering a wide range of standard, high quality products aswell as customised products designed to satisfy specific needs and requirements thanks to the support of our technical department.

Evidence of the high quality of our products lies in the fact that Sotrashas been cooperating with compressor manufacturers for a long time and on a regular basis, providing expertise and technical solutions, developing new products with OEMs, as well as providing assistance to the numerous small, medium and large firms which are all part of the wide network of Sotras’ customers all over the world.

This manual presents our standard product specifications regarding Sotras business units:

Filters and products for compressorsFilters and products for vacuum pumpsCompressed air filter and accessories

and integrates Sotras’ new Customer Service Support Department,whichguarantees a specific and prompt service to customers around the globe.

Sotras help line 0039.011.262.22.22

E-mail: [email protected] [email protected]

www.sotras.com

EXIT BORGARO

EXIT CASELLE

VILLARETTO

MILANO / AOSTA

TORINO

SAVONAFREJUS

S O T R A S

CASELLEAIRPORT

S O T R A S

ORBASSANO

SAVONA

PIACENZA

CASELLEAOSTA

MILANO

VILLARETTOBORGARO

TORINO

SOTRAS

S O T R A SBORGARO TORINESE

TORINO

MILANO

ROMA

S O T R A S

4

FILTERS AND PRODUCTS FOR COMPRESSORSAIR-OIL SEPARATORSFILTER HEADS & ADAPTERSAIR FILTERSSPIN-ON OIL FILTERS

FILTERS AND PRODUCTS FOR VACUUM PUMPSDEMISTERSVACUUM AIR FILTERSSPIN-ON OIL FILTERS

FILTERS AND PRODUCTS FOR COMPRESSED AIRCOMPRESSED AIR FILTERSACCESSORIES

PRATICAL ADVICEPREMATURE INCREASE IN PRESSURE DIFFERENTIALEXCESSIVE USE OF OILCOLLAPSED SEPARATOR CAUSESFLASH FIRES

QUALITY CONTROL AND GUARANTEEQUALITYGUARANTEE

S O T R A S

5

FILTERS & PRODUCTSFOR COMPRESSORS

AIR-OIL SEPARATORS

6

During the last century compressed air became associated with many industrial applications and compressor manufacturersfocused their attention on rotary screw and vane compressor whose compression systems use lubricating oil as a coolant. Hence the necessity of using air/oil separators.

Sotras designs and manufactures separators specifically for installation in rotary screw and rotary vane compressorsand they are available in vertical, horizontal and spin on configurations.Their purpose is to separate the oil droplets from the compressed air, thereby producing cleaner air and allowing theoil to be scavenged and re-circulated in the compressor.

Sotras separators are manufactured to satisfy OEM’s needs in terms of:- Physical principle of air/oil separation- Element dimensions according to the compressor’s performance and tank dimensions.- Oil consumption to ensure a correct functional performance- Use of high grade filtration and separation media to ensure the best quality of clean air needed for industrial applications.Additionally it is very important to highlight that Sotras separators can be used with all types of oils, whether standard, mineral based, synthetic or partially synthetic.In order to decide which is the best separator to be used for a specific compressor, OEMs have to consider what level ofseparation needs to be achieved, in other words to target the minimum of parts per million of residual oil content required. Then a technical solution is needed in order to reduce the oil concentration in the air.Often OEMs need to consider a pre-separation system, which will reduce the PPM and increase the life of the air/oil separator.

Graph 1

Graph 2

7

S O T R A SCONSTRUCTION AND SEPARATION:

Corrosive resistant materials are used in the construction of the air/ oil separators. Careful welding procedures and theuse of the latest twin pack adhesive ensure that the element has high mechanical strength and can endure operatingtemperature up to 120°C.Normally, the air and oil mixture passes from the outside to the inside of the separator and the coalescing effect iscarried out through a multi stage separation process resulting in the recovery of the oil and producing clean air.

At a nominal working pressure of 7 bar, the pressuredrop on a new element varies between approximately0.15 and 0.25 bar. At other working pressures, the pressure drop isproportional to the air velocity across the separator(graph 2)By using our separators, the oil carryover after separation is limited to about 1 to 3 ppm.The life of the separator depends on many

PRESSURE DROP - EFFICIENCY AND PERFORMANCE

Type Pressure drop at General specificationsnominal flow rate (bar)

single wrapped 0,16 low production costs, good performance and long life spandouble wrapped 0,18 excellent performance on small dimensions or long life spanpleated 0,15 low pressure droppleated+wrapped 0,17 low pressure drop and excellent separation levelswith pre-separation fleece 0,2 for applications showing high oil percentage before

separation or under particular environmental conditionsspin on 0,25 for easy maintenance and small flow rates

factors: the designs and regular maintenance of thecompressor, clean environment, working temperature,quality of the air and oil filters. To ensure maximum separator efficiency, the jointsmust create a perfect seal. Experience has shown that

through correct installation and also usingthe correct type of oil, Sotras separatorscan have a life expectancy of many thousands of hours.

STANDARD SEPARATORS

8

DF 5010DB 2001DB 2002DF 5005DF 5006DB 2003DB 2006DB 2057DF 5009DB 2009DB 2074DB 2085DF 5004DB 2021DB 2012DB 2160DB 2186DB 2022DB 2018DB 2105DB 2319DB 2132DB 2020DB 2024DB 2104DB 2026DB 2027DB 2118DB 2130DB 2029DB 2353DB 2030DB 2082DB 2025DB 2138DB 2051DB 2102DB 2055DB 2061DB 2124DB 2084DB 2089DB 2147DB 2090DB 2382DB 2167DB 2126DB 2129

11,5223

3,53,53,54

4,54,55

5,56,57778

8,599

9,5121212

12,51416

16,5171819

19,52020

21,522

23,523,525

25,52829

34,539404344

extintintextextintintintextintintintextintintintintintintintintintintintintintintintintintintintintintintintintintintintintintintintintintintint

611661126122611321124211211221511121211222125221

7613513596136135170135108170135170136275170170170275220220220170220275220300300220300300300300400275275300300300400220275300300300393300400475

M22X1,58888

M24X1,5M39X1,5

8812275

M32X1,512275108

M39X1,5219122108108219165157157108165219157243243157219243219243314219210243219243314157210219243219304219314398

6216517062991702001709320017020099328200200200328273273273200273324273348355288345355343355439324325348350355439273325355355355439355439740

1231402002101773052301602603052001803032504352302303054302302303056004483054455004003056003146605207504007504008206206125005001000600510700600900

0121200121200120000120012120001212012120012012012012012000012050019

SOTRAS Ref. h2 (mm)h1 (mm)d4 (mm)d2 (mm)d1 (mm)DrawingTypeNominal flow rate (m3/min)

The table shows some of Sotras standard separators; special types are available on request.

The data is indicative and based on 7 bar working pressure

9

S O T R A S

(DRAW. 3)DOUBLE WRAPPED+ FLEECE

(DRAW. 1)SINGLEWRAPPED

(DRAW. 2)DOUBLEWRAPPED

(DRAW. 4)PLEATED

(DRAW. 5)PLEATED + WRAPPED

(DRAW. 6)SPIN-ON

TYPES AND DRAWINGS

int. ext.

FILTER HEADS & ADAPTERS

10

NP 0001NP 0002NP 0003

NP 0004

M22X1,5M24X1,5M32X1,5

M39X1,5

19,219,828,1

35,8

141522

30

121319

26,5

M 27X1,5M27X1,51''-1/4 G

1''-1/4 G

161620

20

323241

41

181818

18

555

5

SOTRAS Ref. h4 (mm)

115195137

155

h5 (mm)

323250

50

S

DF 5010DF 5005DF 5009DF 5004DF 5006

Corresp. separatorh3 (mm)h2 (mm)h1 (mm)d5d4 (mm)d3 (mm)d1 d2 (mm)

For OEMs that use spin on separators but do not make filter heads and adapters in house, we are able to offerdifferent options.Besides simple separator heads, SOTRAS is also able to provide models with integrated connectors for oil cartridges.Depending on the OEM’ s requirements it is possible to order the filter head alone or together with the relevantelements - separator and oil filter.On request, we provide information regarding heads with thermostatic valves, minimum pressure valves and visualoil indicators.

AIR-FILTERS

11

Besides being able to provide a wide range of adaptable air cartridges, SOTRAS can offer OEMs a series of airfilters that do not require a housing. These filters are recommended for 1 to 12 m3/min flow rates and can beinstalled vertically or horizontally.This type of solution offers a low pressure drop and very simple installation and replacement procedures. (On specific requests we can offer fibreglass or oiled cellulose filtering media).

12

SA 6663SA 6972SA 6620SA 6696SA 6905SA 6718

110110130164164230218

514176766010078

9393

125135135116282

25252525253535

112446

12

SOTRAS Ref. Nominal flow rate (m3/min)h2 (mm)h1 (mm)d1 (mm) d4 (mm)

SPIN-ON OIL FILTERS

13

Thanks to its experience in the hydraulic sector, SOTRAS has developed a range of oil filters, especially suitable forscrew and vane compressor applications, “bearing in mind„ that these filters will have to endure sudden changes andextreme limits in pressure and temperature. The oil filters that SOTRAS offers are usually of the spin-on type andcan be provided with a by pass valve, if it is not already to be found on the heads or in the lubrication circuit.Generally the most commonly used filtering media is made of cellulose, however fibreglass and metallic meshversions are available on request.Every batch undergoes stringent laboratory performance tests in terms of resistance to cyclic and maximum working pressure.

SH 8118SH 8196SH 8113SH 8152SH 8153SH 8112SH 8119SH 8154SH 8155SH 8143SH 8146SH 8130SH 8147SH 8149SH 8107SH 8110SH 8150SH 8144SH 8114SH 8108SH 8145SH 8109

76937676939393939396939693108939393127136108127136

626262626262626262626262626262626298999398100

3/4'' 16-UNF3/4'' 16-UNF3/4'' 16-UNF3/4'' 16-UNF3/4'' 16-UNF3/4'' 16-UNF1'' 12-UNF

3/4'' 16-UNF1'' 12-UNF

3/4'' G1'' 12-UNF

3/4'' G1'' 12-UNF1'' 12-UNF1'' 12-UNF1'' 12-UNFM 20x1,51'' 1/4 G

1'' 1/2 16-UN1'' 1/8 -16 UN

1'' 1/4 G1'' 1/2 16-UN

9558

12514097

143143144172146170193210210210212212182177260228302

0,120,120,12

--

0,120,12

---

0,12-

0,120,12

-----

0,12--

2,50,82,53,52,52,52,52,52,5-

2,5-

2,51,22,52,52,5--

2,5-

2,5

15152020254040404040455570707070708095

100150180

SOTRAS Ref.

14141435251414252514141414141425301420141220

by pass Valve (bar)

Non-returnValve-(bar)h1 (mm)d3d1 (mm) d2 (mm)

Nominalflow rate(l/min)

Max.operating

Pressure(bar)

FILTERS & PRODUCTSFOR VACUUM PUMPS

14

S O T R A S

DEMISTERS

15

The media used in our separators enables us to obtainexcellent air/oil separation rates up to 1-3 mg/m3.All oil separators are manufactured using materials towithstand high pressures and temperatures and to minimisemoisture induced deterioration.

In order to achieve the best possible separation efficiency andlong working life of the element it is essential that regularmaintenance procedures are followed and joints are appliedcorrectly, as well as the use of good quality air and oil filters.

DA 1050DA 1051DA 1022DA 1060DA 1120DA 1013DA 1014DA 1111DA 1015DA 1047DA 1020DA 1048DA 1030DA 1049

54,571,579,5727970707270721067210672

6874

117,5132144175200200255250218375284500

25,532,5453546404035403572357235

2,52,53,580008080808

11123332323232

0,250,40,70,80,90,91,11,21,41,52,22,22,82,9

SOTRAS Ref. Flow rate(m3/min)Drawingh2 (mm)h1 (mm)d2 (mm)d1 (mm)

DRAW. 1DRAW. 3

DRAW. 2

VACUUM AIR FILTERS

16

Sotras offers a wide range of filters to suit most requirements in this field and the elements are usuallyinterchangeable with those produced by other leading manufacturers.Steel housings are treated with a special protective coating thereby guaranteeing a longer durability. They also undergothorough tests to ensure the seals withstand high vacuum levels.The elements have high dust retention and are available with paper media (having a normal filtration rate of 5microns) as well as glassfibre media for special applications.

17

SA 6654SA 6058SA 6647SA 6952SA 6059SA 6819SA 6061SA 6635SA 6820SA 6821SA 6648SA 6822SA 6649SA 6823SA 6060SA 6824SA 6650SA 6652SA 6825SA 6749SA 6750

SA 6715SA 6091SA 6091SA 6120SA 6120SA 6120SA 6122SA 6122SA 6122SA 6122SA 6651SA 6651SA 6096SA 6096SA 6096SA 6096SA 6095SA 6095SA 6095SA 6005SA 6025

G 3/8''G 3/4''G 1/2''G 1''

G 1''1/41''1/4 NPT

G 1''1/4G 1''1/4

1''1/4 NPT1''1/2 NPT

G 1''1/21''1/2 NPT

G 2''2'' NPTG 2''1/2

2''1/2 NPTG 3''G 4''

4'' NPTG 3''G 4''

80110110133133133170170170170170170200200200200270270270280360

FFFFFFFMFFFFFFFFFFFFF

667676858585141141141141170170240240240240180180180395590

121414171717171717171818181818185050505050

39535353535393939393124124124124124124145145145330400

SOTRAS Ref. ElementRef.h3 (mm)

45545478787896969696100100114114114114165165165190230

h4 (mm)

24424285969610810810810819219231031036036055072072010801260

flow rate(m3/h)h2 (mm)h1 (mm)d2 (mm)MALE-

FEMALEd1

The oil filters that Sotras offers for vacuum pumps applications have the same characteristics as the products usedfor compressors

( See pag. 13 )

SPIN ON OIL FILTERS

FILTERS & PRODUCTSFOR COMPRESSED AIR

18

S O T R A S

19

SM 9001SM 9002SM 9003SM 9004SM 9005SM 9006SM 9007SM 9008SM 9009SM 9010

6078120198335510780100015002760

878787130130130130164164250

3/8" 1/2"3/4"1"1"

1 1/2"1 1/2"

2"2"3"

21212143434343484874

20920927931541551571582310731202

7575160135235335525520770780

16161616161616161612

SOTRAS Ref. H3 (mm) Max operatingpressure (bar)H2 (mm)H1 (mm)D1 (mm)ConnectionsCapacity

(m3/h at 7 bar)

COMPRESSED AIR FILTERSDue to the continuous demand of users of compressed air for clean, high quality air, Sotras offers a range of coale-scing filters specifically designed to suit most requirements. Our established experience enables us to offer simple,efficient and high quality products at competitive prices. There are four series of elements available for various typesof applications, depending on the level of filtration required. ( See pag. 20 )






SOTRAS Ref.

FILTERHOUSING FILTER ELEMENTS

ACT.CARB.(series 4)

MICROFILTER(series 3)

FINE FILTER(series 2)

PREFILTER(series 1)

1234

30,10,010,01

0,030,050,060,12

-0,50,010,005

SERIES

NOMINAL INITIAL

PRESSUREDROP (bar g)

OIL REMO-VAL DOWNTO (mg/m3)

PARTICLEREMOVALDOWN TO(micron)

20

PRE FILTERS“Series 1” Coarse filtration and dust removalAir flow through filter element- out to in

ACTIVATED CARBON FILTER“Series 4” Oil vapour and odour removalParticle removal below 0.01micron. Maximum residual oil content down to 0,005 PPM. Air flow through filter element-in to out

MICRO FILTERS“Series 3” High efficiencyParticle removal down to 0.01 micron. Maximum residual oil content down to 0,01 PPM. Air flow through filterelement-in to out

FINE FILTERS “Series 2” General purpose protection Particle removal down to 0,1 micron. Maximum residual oil content down to 0,5 PPM. Air flow through filter element-in to out.

Sotras also offers a wide range of alternative elements suitable for other makes of housing.

ACCESSORIES

21

Cyclon kits, differential pressure gauges, manual, automatic condense drains and technical specifications areavailable for all types.

PRACTICAL ADVICE

22

Premature increase in pressure differential

This usually occurs when compressors work under the following conditions:a) Air intake filter and oil no longer efficientb) Unsuitable or heavily contaminated oilc) Water contamination-recognised by rust deposits in separator tankTo help in avoiding these problems, there should be frequent replacements of the Air and Oil filters and the oil shouldbe changed completely at regular intervals. Check for deposits of’ varnish’ which can quickly block a separator.Compressor should not be run at excessively high temperatures.

Excessive use of oil

This normally occurs under the following circumstances:a) Separator not changed at the appropriate time. If the separator has reached the end of its lifespan or has worked inarduous conditions and is not replaced, it can suffer structural damage (collapse) or media breakdown causing oil carry-over.

b) Blocked or malfunctioning scavenge tube. This situation increases the level of oil inside the separator and theamount of oil carry-over. To avoid this problem, the scavenge tube must be checked for correct length at everyseparator change and kept free from blockage.

c) Incorrect oil level in tank. Overfilling with oil alters the pre-separation process and increases the quantity of oil in theair/oil mist thereby reducing the efficiency of the separator. “Foaming” created by the oil can also create this situation.

d) Gaskets applied incorrectly or use of unsuitable or used gaskets. When installing a new separator the incorrectapplication of joints (bad seal) can cause heavy movements of oil thereby by-passing the separating system.

e) Inefficient separation system. In some instances, the design of the compressor separation system is inefficient.In these cases the manufacturers improve the separation efficiency by adding baffles or through modification ofseparations by adding pre-separation media to the outside of the element.

Collapsed separator causes

This normally occurs under the following circumstances:a) Separator excessively contaminatedb) Sudden surges caused by:- malfunctioning valves- sudden release of air to atmosphere (mobile compressors)c) Rotary compressors working in parallel with reciprocating compressors without a suitable air receiver.

Flash firesThese are very rare and are caused by several factors occurring simultaneously and not directly related to the Air/Oil separator. It is good practice to ensure that the gaskets have a reliable form of grounding by the use of suitable materials (at least one or two metal staples or metal foil) so that there is contact between the element and the separator tank.

Our products regularly undergo stringent quality control and only very seldom the malfunctioning of the compressorhas to be ascribed to the filter itself. Here below are listed some of the most common causes which lead on to an improper functioning of the machine.

23

S O T R A SQUALITY CONTROL AND GUARANTEE

The efficiency of our separators is tried through Johnson or Balston tests as well as the use of artificial smoke.All types of filters are passed to our Quality control Department for approval before being marketed and

the performance of every batch in terms of resistance to cyclical and maximum working pressure regularly undergoes stringent laboratory tests

We would like to emphasise that Sotras filters undergo stringent quality control and are frequently tested in order to ensure satisfactory operation in the application of which they are designed.

Evidence of the high quality of our products lies in the fact that Sotras manufactures original equipment for someof the most important compressor manufacturers, to some of which Sotras guarantees product exclusivity.

We guarantee that filters produced by Sotras are free from defects either in materials or construction, always provided that the machinery is maintained in accordance with manufacturers’ recommendations and filters

are correctly installed and changed.

Sotras will replace any item found to be defective as described above but will not be held responsible for any other replacement or contingencies or consequential loss.

In addition Sotras manufacturing quality system has had approved certification to UNI EN ISO 9002-94 since 1999.

In year 2003, Sotras has gained a new certification toUNI EN ISO 9001-2000.

VIA DONATELLO, 13 - 10071 BORGARO TORINESE (TORINO) - ITALYTEL. 0039.011.262.22.22 - FAX 0039.011.262.41.41

[email protected]

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Documents

Sotras Manual