the right air oil separator for any installation situation oil sep.pdf · the right air oil...

The right Air Oil Separator ...

Types Figure Installation site Residual oil contentmg/m3

1 to 3 mg/m3

Operatingtemperature

120 °C

Standard WrapElement

Page 5

Depth Sepa-rator Element

Page 7

Air Oil Sepa- rator Box

Page 9

Air Oil Sepa-rator Filter

1

Air Oil Sepa-rator Elementfor vacuumpumps

Page 13

inpressure reservoir


upright on pressurereservoir

suspended in the compressed

air pipe


Pressuredrop

for a given nominal flow rate

bar

Available nominal flow rates

(at 7 bar (0.7 MPa)

... for any installation situation

Advantages

0.17

0.2

0.25

0.3

0.25

2 to 42 m3/min

3.5 to 39 m3/min

1 to 5.5 m3/min

1 to 11 m3/min

0.1 to 2.9 m3/min

• High process reliability by using top quality filtration media

• Low oil consumption due to low residual oil content

• Thoroughly tried and tested and reliable



• Space saving achieved through compact design


• Simple and time-saving assembly and disassembly

• Cost advantages with services as compared with traditional air oil separators



• Simple and time-saving assembly and disassembly

• Cost advantages with services as compared with traditional air oil separators




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2

MANN Air Oil Separators...

The use of compressed air is now an integralfeature of every industrial firm. Compressorsand vacuum pumps are used in the construc-tion industry, mechanical engineering and inhighly sensitive sectors such as the foodstuffs,pharmaceuticals and electrical engineeringindustries. MANN Air Oil Separators are impor-tant quality components in the compressed airprocessing chain.

Functional descriptionMANN Air Oil Separators work according to the„principle of coalescence“. Micro-glass-fibrelayers separate drops of oil from the compres-sed air and return them in large drops to the oilcircuit of the compressor. The separation pro-cess is effective right down to the submicronrange. This ensures that oil consumption in thecompressors and oil entrainment into the com-pressed air networks are kept to a minimum.Vapour oil particles are not separated.MANN Air Oil Separators can be used with alltypes of standard compressor lubricating oils,irrespective of whether they are mineral-based,synthetic or partially synthetic products.

Separation of oil dropsDepending on the size of the drops, variousphysical separation effects result in the finedrops being adsorbed by the micro-glass fibres.The number of fibres, fibre diameter and flowvelocity have a major impact on separation effi-ciency. If the design is modified, interaction bet-ween inertia, sealing and diffusion effects isoptimised.The larger drops produced in the first separati-on phase by the coalescence of fine drops arepressed through the glass-fibre layer and sinkto the bottom on the dry side under the influen-ce of gravity. The remaining air-borne proportionof smaller drops is separated in the secondphase. Selection of the correct materials in con-junction with low flow resistances ensures thatnearly all oil drops left in the air flow can beseparated or drained off. This also applies toload fluctuations around the nominal utilisationpoint.

Return of separated oilDepending on the make of compressor, oil isreturned in a number of different ways. In thestandard design of MANN Air Oil Separators, oilflows from the outside to the inside and thedrainage oil is drawn off on the dry side througha centrally positioned pipe running from thebase cup of the separator.

Oil separation according to the «principle ofcoalescence»


3

DesignMANN Air Oil Separators contain either two orthree layers. The first separation layer is normal-ly the fine particle layer made of borosilicateglass fibres in defined layer thicknesses andpore sizes. These almost binder-free microfibrepapers ensure resistance to different types oflubricating oil even at relatively high operatingtemperatures. The second separation layer ismade of a polyester fleece.In difficult pre-separation conditions, a third pre-separation layer can protect the other two lay-ers against overloading, thus increasing the ser-vice life of the air oil separator. Please askabout pre-separation layers.In accordance with the requirements of thetrade association of the chemical industry, themetal parts of MANN Air Oil Separators forcompressors have an electrically conductiveinterconnection in order to transfer any staticcharges reliably. Suitably prepared mountingseals produce conductive connections to thecompressor housing.

... for constant compressed air quality

Quality Features• High resistance to differential pressure• Operating temperature: up to 120 °C• Residual oil content: 1 to 3 mg/ m3 or ppm

(for nominal flow load)• Nominal flow rates: (at 7 bar/0.7 MPa)

• Standard wrap element: 2 to 42 m3/min• Depth separator element: 3.5 to 39 m3/min• Air oil separator box: 1 to 5.5 m3/min• Air oil separator filter: 1 to 11 m3/min• Air oil separators for vacuum pumps:

0.1 to 2.9 m3/min

Flow resistanceDepending on their type, MANN Air OilSeparators have flow resistances of between0.17 bar (17 KPa) and 0.22 bar (17 KPa), referred to the oil-moistened operating state at nominal volumetric flow and at operatingtemperature.

MANN Air Oil Separator Element with two-layerseparation

MANN Air Oil Separator Element with three-layer separation

Flow resistances of MANN Air Oil SeparatorElements

0,4Widerstand (bar)

0,3

0,2

0,1

050 70 80 90 100 140

Rel. Nennbelastung (%)15013012011060

Resistance (bar)

Relative nominal load (%)

0.4

0.3

0.2

0.1

0


4

MANN Standard Wrap Element ...

Design and functionThis product is suitable for flow from the outsi-de to the inside. It can be used for the entirerange of current versions of screw-type and sli-ding vane compressors.The standard wrap elements are particularlyinsensitive to design variations and achieveoptimal results with regard to separation effi-ciency and service life.

Pressure dropThe pressure drop at nominal flow rate and at 7 bar (0.7 MPa) operating pressure with a new element is 0.17 bar (17 KPa). If a higher resistance is permitted, the volumetric flow rate can be doubled without downgrading per-formance.

Pressure resistanceMANN Air Oil Separators are designed for diffe-rential pressures of up to 5 bar (0.5 MPa).

Separation efficiencyThe residual oil content at nominal flow

rate and at 7 bar (0.7 MPa) operatingpressure is approximately 1 to 3 mg/m3 (1 to 3 ppm).

Service lifeThe rise in flow resistance and thus

service life primarily depend on thecleanness of the oil and the quality of the air

filter. A service life of several thousand hourscan be achieved with a well-functioning system.

Fitting adviceMANN Standard Wrap Elements are available ina variety of sizes. They will only function pro-perly when there is no leakage between the wetand the dry sides. Air should be guided in sucha way as to prevent the air oil stream impactingdirectly on the surface of the filter element.

Installation of MANN Standard Wrap Element inpressure reservoir

Seals

Compressed air inlets for oil saturated air (3 inlet alternatives)

to oil injection

oil-free compressed air


5

... tried and tested thousand times

Part No. Packaged

model

49 000 51 53149 000 51 41149 000 51 20149 000 51 12149 000 51 11149 000 51 10149 000 51 17149 000 51 32149 000 51 13149 000 51 19149 000 51 18149 000 51 22149 000 51 52149 000 51 48149 000 51 54149 000 51 581

Flowrate1)

[m3/min]

23.53.54.56.589

121214171920242942

d1

135135170170170275220275220300300300275300300475

d2

170170200200200328274328274355355355324355355570

d3

8888

123123123220165220165245245245220245245400

h1

200305230305435305435450600500600660750820

1 000900

h2

12121212121212121212121212121220

Dimensions in mm

Flow rate according to DIN 1945 at 7 bar (0.7 MPa) operating pressure. 1)

Specially adapted sizes are available on request.

d3

d2

h1

h2

d1


6

MANN Depth Separator Element ...

Design and functionThis product takes up very little space and issuitable for the entire range of current versionsof screw-type and sliding vane compressors. Inthe depth separator element, oil flows from theoutside to the inside.

Pressure dropThe pressure drop at nominal flow rate and at 7 bar (0.7 MPa) operating pressure with a newelement is approx. 0.2 bar (20 KPa). If a higherresistance is permitted, the volumetric flow ratecan be increased to 1.5 times the nominal flowrate without downgrading performance.

Pressure resistanceMANN Depth Separator Elements are designedfor differential pressures of up to 5 bar (0.5 MPa).

Separation efficiencyThe residual oil content at nominal flow rate andat 7 bar (0.7 MPa) operating pressure is approx.1 to 3 mg/m3 (1 to 3 ppm).

Service lifeThe rise in flow resistance and thus service lifeprimarily depend on the cleanness of the oil and the quality of the air filter. A service life ofseveral thousand hours can be achieved with awell-functioning system.

Fitting adviceMANN Depth Separator Elements are availablein a variety of sizes. They will only function pro-perly when there is no leakage between the wetand the dry sides. Air should be guided in sucha way as to prevent the air oil stream impactingdirectly on the surface of the filter element.

Installation of MANN Depth Separator Elementin pressure reservoir

Seals

Compressed air inlets for oil saturated air (3 inlet alternatives)

to oil injection

oil-free compressed air


7

... high performance in a confined space

Part No. Packaged

model

49 301 53 13149 301 53 10149 302 53 13149 303 53 12149 303 53 11149 304 53 10149 305 53 11149 305 53 10149 306 53 102

Flowrate1)

[m3/min]

4.56.59

1620222833.539

d1

135170170300275300300300300

d2

170200200355328355355355355

d3

75109109220209220220220220

h

200230305305400400500600700

Dimensions in mm

Flow rate according to DIN 1945 at 7 bar (0.7 MPa) operating pressure.1)

Specially adapted sizes are available on request.

d3

d2

h

d1


8

MANN Air Oil Separator Box ...

Flow ratesMANN Air Oil Separator Boxes are available fornominal flow rates of 1 m3/min up to 5.5 m3/min(35 to 194 cfm) at an operating pressure of 7 bar (0.7 MPa).

Pressure dropThe pressure drop at nominal flow rate and at 7 bar (0.7 MPa) operating pressure is approx.0.25 bar (25 KPa) with a new element.

Pressure resistanceThe housings of the MANN Air Oil SeparatorBoxes are designed for operating pressures upto a maximum of 20 bar (2 MPa) or a maximumof 14 bar (1.4 MPa) (please see table on page10). The built-in filter elements can withstandpressure differences up to 5 bar (0.5 MPa).

Separation efficiencyThe residual oil content of the compressed airat nominal flow rate and 7 bar (0.7 MPa) opera-ting pressure is approximately 1 to 3 mg/m3

(1 to 3 ppm).

Service lifeThe rise in flow resistance and thus service lifeprimarily depend on the cleanness of the oil andthe quality of the air filter. A service life of severalthousand hours can be achieved with a well-functioning system.

Fitting adviceMANN Air Oil Separator Boxes are fitted verti-cally (Fig. 1) by hand on the firmly installed filterhead using a suitable adapter union. MANN+HUMMEL recommends installation in amaintenance-friendly position.

MaintenanceThe air oil separator boxes must be replaced ifthe flow resistance reaches 1 bar (0.1 MPa). The box may only be replaced when the systemis depressurised. A commercially available beltwrench is sufficient to remove the box. The boxis fitted and tightened manually.

Fig. 1

pressure-proof housing

Adapter union(supplied)

O-ring

Filter head(Srew-on base,not supplied)

De-oiled compressed airoutput

De-oiled com-pressed air

Extra separator

pressure-sta-ble supporttube

Separated oil

Inlet of air-oil mixture

Fineseparator


9

... for simple maintenance

MANN Air Oil Separator Box (Fig. 1)

Part No.

LB 719/2LB 962/2LB 1374/2LB 11 102/2LB 13 145/3

max.working pressure[bar] [MPa]

20 220 220 214 1.420 2

Flowrate1)

[m3/min]

12345.5

d1

M 22 x 1.5M 24 x 1.5M 39 x 1.5M 32 x 1.5M 39 x 1.5

d2

6262

10093

100

d3

7171

111104111

d4

7693

136108136

d5

8096

140110140

h1

127212177260302

Dimensions in mm and inches

Adapter Union (Fig. 2)

Part No.

21 024 15 98121 027 15 99121 036 15 99121 042 15 991

suitable forseparator box

LB 719/2LB 962/2LB 11 102/2LB 1374/2LB 13 145/3

d1

M 22 x 1.5M 24 x 1.5M 32 x 1.5M 39 x 1.5

d2

M 24 x 1.5M 27 x 1.5M 36 x 1.5M 42 x 1.5

d3

14152230

d4

19.219.828.135.8

h1

135135155175

h2

383841.547.5

h3

25.425.427.434.4

h4

6667

sw

27324146


Flow rate according to DIN 1945 at 7 bar (0.7 MPa) operating pressure. 1)

d4

d5

h1

d3

d2

d1

d4

d3

h2

h3h4

15

h1

40SW

d2

d1

Fig. 1 Fig. 2


10

to theconsumer

from thecompressor

to the screw

MANN Air Oil Separator Filter ...

Flow ratesMANN Air Oil Separator Filters are available fornominal flow rates of 1 m3/min up to 11 m3/minat a compressor pressure of 7 bar (0.7 MPa).

Pressure dropThe pressure drop at nominal flow rate and at 7 bar (0.7 MPa) operating pressure is approx.0.3 bar (30 KPa) with a new element.

Pressure resistanceThe housings of the MANN Air Oil SeparatorFilters are designed for operating pressures upto a maximum of 20 bar (2 MPa) or a maximumof 14 bar (1.4 MPa) (please refer to values in thetable on page 12). The built-in filter elementscan withstand pressure differences up to 5 bar(0.5 MPa).

Separation efficiencyThe residual oil content of the compressed airat nominal flow rate and at 7 bar (0.7 MPa) operating pressure is approx. 1 to 3 mg/m3

(1 to 3 ppm).

Service lifeThe rise in flow resistance and thus service lifeprimarily depend on the cleanness of the oil andthe quality of the air filter. A service life of sever-al thousand hours can be achieved with a well-functioning system.

Fitting adviceThe air oil separator filters are fitted in an easilyaccessible position either vertical or suspendedin the pipe downstream of the compressed airtank. Please observe the marked flow direction.The oil return pipe supplied by the customer(steel pipe 8x1C-PHR) is oiled by the screwconnection in the head. The steel pipe is notpart of the scope of supply.

MaintenanceThe air oil separator boxes of the filters must be replaced if flow resistance reaches 1 bar (0.1 MPa). The box may only be replaced whenthe system is depressurised. A commerciallyavailable belt wrench is sufficient to remove thebox. The box is fitted and tightened manually.

Installation of the MANN Air Oil Separator in thecompressed air pipe

Fig. 1


11

... low maintenance and flexible installation

Part No.

49 303 62 10149 306 62 10149 308 62 10149 312 62 10149 316 62 10149 330 62 101

Matchingseparator box

LB 719/2LB 962/2LB 1374/2LB 11 102/2LB 13 145/3

2x LB 13 145/3

Fig.

222223

a

9595

135130135320

b

505054815468

c

127212177260302302

d

G 3/4

G 3/4

G 11/4

G 11/4

G 11/4

G 2

d1

3636505050–

d2

7693

136108136136

e

343441464158

f

47.547.55647.556

–


Flow rate according to DIN 1945 at 7 bar (0.7 MPa) operating pressure.1)

max. workingpressure

[bar] [MPa]

20 220 220 214 1.420 220 2

Flowrate1)

[m3/min]

12345.5

11

M 10 20 tief

f

b

d

c

e

a

d1

d2

50- 0,8+

25- 0,8+

35- 0,3+

d

b

e

80- 2+

a

80- 0,3+ 80- 0,3

M 10 20 tief+

d2

Fig. 2 Fig. 3

M 10 20 deep

M 10 20 deep

0.30.3

0.3

0.8

0.8


12

MANN Air Oil Separators for vacuum pumps ...

Design and functionThis product is designed for flow from the outsi-de to the inside. The air oil separators listed inthe table on page 14 are particularly suitable forintegration in oil-flooded vacuum pumps. Anyinstallation position is acceptable.

Pressure resistanceThe MANN Air Oil Separators for vacuumpumps are designed for differential pressures ofup to at least 1.5 bar (150 KPa).

Separation efficiencyThe residual oil content at nominal air flow isapprox. 1 to 3 mg/m3.

Service lifeThe rise in flow resistance and thus service lifeprimarily depend on the cleanness of the oil and the quality of the air filter. A service life ofseveral thousand hours can be achieved with awell-functioning system.

Fitting adviceThe full separation efficiency of the air oil sepa-rators is only available fully when there is noleakage between the wet and dry sides.


13

... flexible installation

Part No.

49 000 52 10849 000 52 35149 000 52 35249 000 52 35349 000 50 61149 000 52 39149 000 52 10749 000 52 10349 001 52 11249 001 52 15249 001 52 151

Flowrate

[m3/min]

0.10.250.40.70.91.21.41.451.82.22.9

Fig.

11111212122

d1

3055728080727072707272

d2

1025.532.245.245–

40–

40––

d3

–––––

35–

35–

3535

h

607580

125145202250252330377502


Customized versions are available on request. Please contact us.

d2

d1

h

d3

d1

h

9- 1+

Fig. 1 Fig. 2


14

Practical Tips and Tricks

Service life of air oil separatorsDirt deposits, e.g. old oil products, air contami-nation or abrasion reduce the service life of airoil separators. Various final differential pressuresare determined by the user. In practice, finalvalues of between 0.8 bar (80 KPa) and 1 bar(100 KPa) are normal for compressors andapprox. 0.5 bar (50 KPa) for vacuum pumps.Fouling which accumulates in the air oil separa-tor may also increase on account of higher oilflow. This is measurable as drainage flow. Thedrainage flow volume depends directly on thestructural design of the pre-separation mecha-nisms in the compressor. Optimum values fordrainage flows are around 1 g of oil per m3 ofoil.

Measures to secure an economic service lifeof air oil separatorsCorrect oil care is a basic precondition for asatisfactory service life of air-oil separators.Generally speaking, the service life of air oilseparators is only restricted by deposits of solidparticles (old oil products, abrasion) in the fineseparation layer and the resulting increase indifferential pressure. The entry of fouling into thelubricating oil can be restricted by changing theair and oil filters in good time and by observingthe oil change intervals. The amount of foulingentering the air oil separator is thus kept to aminimum and this has a positive effect on main-tenance intervals. The selection of oil also playsan important role as regards service life. Only

approved, aging-resistant and water-insensitiveoils should be used. Unsuitable oils with insuffi-cient oxidation resistance may block the air oilseparator even after a relatively short operatingperiod due to the build-up of deposits whichhave a similar consistency to jelly. Acceleratedoil aging is the result of high operating tempera-tures. Accordingly, attention must be paid to thesupply of cooling air and to cooler contaminati-on. During oil changes, all used oil should beremoved to avoid initial damage caused by resi-dual oil or incompatibility between oils if themake of oil is changed. In order to take fulladvantage of the long service life of syntheticoils, any existing mineral oil residues must beremoved completely.In rare cases, oil may age prematurely due togaseous foreign substances which are entrainedin with the ambient air.

Reduced service life due to operational faultsin compressorsMANN Air Oil Separators are insensitive to nor-mal back flows or pulsation. However, abnor-mally large backflows may lead to defects in thefine separation layer of the air oil separators.This damage is generally not visible and there-fore cannot be detected with the naked eye.However, even small defects in the separationlayers may produce higher residual oil contents.In order to identify this damage, extensive testssuch as residual oil measurements and destruc-tive tests must be carried out.

Economic service life

Operating conditionsOil care

Oil change interval

Oil filter change interval

Air filter change interval

Oil compatibility

Oil contamination

Aging resistance

Insensitivity to water

Compressor suitability

Air separation efficiency(LVA DIN 51381)

Ambient temperature

System cooling,Oil temperature

Foreign harmful bodiesin air

Selection of oil


15

Practical Tips and Tricks

Residual oil measurementsResidual oil contents are measured most effec-tively using suitable absolute filters. In this case,it is important to measure both the oil dropsand the wall flow since larger drops tend to bedeposited on the wall. In order to avoid pro-blems caused by condensation water,MANN+HUMMEL recommends that residual oilmeasurements be carried out in pressure-relie-ved condition. Measuring devices containingelectronic particle counters only detect the air-borne proportion of oil drops and do not takeany account of the wall flow.

Improvements in pre-separation in existingcompressorsIn spite of the above reasons, the air oil separa-tors in compressors with imperfect pre-separati-on may still have an adequate service life ifthree-layer elements are used. The so-calledthird layer consists of an open-pore fleece infront of the fine separation layers and separatesa considerable proportion of the large oil drops.In individual cases, this pre-separation layer canbe retrofitted.

Oil consumption in the compressorOperating and marginal conditions which havean effect on the oil level in the pressure reser-voir of the compressor, oil degasification pro-cesses, the effectiveness of pre-separation andthe drainage system may result in increased oilflow rates in the short or long terms. For exam-ple, blockages in the drainage system lead toan accumulation of oil on the dry side of the airoil separator. Depending on the accumulatedquantity, different quantities of oil may be accu-mulated.

An excessive oil level in the pressure reservoirmay have similar effects. If a marked phaseseparation zone cannot be formed between theoil and air either temporarily or permanently, this will impair the pre-separation of the oildrops and also have a negative effect on theresidual oil content downstream of the air oilseparator after a certain size.Overfilling the receiver tank with oil may lead tothe penetration of abnormally large amounts offoaming oil into the air oil separator under cer-tain operating conditions at low oil temperatures

and when slowly degassing oils are used. The oil flow rate may rise substantially due tooverwetting of the air oil separator.In addition to the above-mentioned influencesand operating faults which have a negativeeffect on oil consumption, the vaporous oil por-tion may reach a considerable level and thusalso simulate faults in an air oil separator.Depending on the type and make of oil, oilvapour contents of up to 10 mg/m3 are possibleat normal operating temperatures of 80 °C.

Protection against corrosionMANN Air Oil Separators are galvanised andthus protected against corrosion.

Increased oil consumption

Blocked drainage line

Type of oilOil vapour content

Overfilled sump

Air releaseOil foam build-up


16

Installation and maintenance tips

Quality is no coincidenceThe quality features and product advantages offilters and elements are often not noticed atfirst glance. It is therefore important, however,to compare service life, separation efficiencyand design features.

Products by MANN+HUMMEL are subjected toquality planning and assurance from develop-ment through to series maturity.

Our quality assurance system satisfies therequirements of DIN/ISO 9001 and incorporatesquality in technical and organisational proces-ses.

An air oil separator or an air oil separator boxmust be changed when it reaches the final diffe-rential pressure which is determined for eachproduct and is dependent on economic consi-derations. MANN Air Oil Separators and Air OilSeparator Boxes are easy to handle and install,and pose no special problems. However, thetime taken to install or replace MANN Air OilSeparators and Air Oil Separator Boxesdepends on the particular installation conditionsand may increase in the case of larger systemswith greater dimensions and componentweights.Whenever an air oil separator is installed orreplaced, care should be taken to ensure thatthe associated seals are in a perfect state andthat they are seated properly. In normal cases,the seals are selected and supplied by the com-pressor manufacturer.In the case of standard elements with flow fromthe outside to the inside and upright installation,special attention must be paid to the dischargeof drainage oil. The scavenge pipe must havethe correct length and extend as far as the basecup of the element.It is very easy to replace the so-called air oilseparator boxes which are merely screwed onor off from the outside.

Zero defect production through FMEADesign FMEA (failure mode and effects analysis)plays a vital role in defect avoidance and thusto achieve zero defect production. FMEA isused with new product developments in orderto detect any weak points in the design and todefine future quality characteristics. In order todetect weak points in production and definetest specifications and processes, design FMEAis supplemented by process FMEA.

MANN+HUMMEL employees are capable ofassuming responsibility for their own work andtest the quality of manufactured products them-selves. Important process parameters and testfeatures are documented in order to monitor themanufacturing process. Quality awards from ourcustomers document the high quality standardsof our products.

A good basis for co-operation.


17

the right air oil separator for any installation situation oil sep.pdf · the right air oil...

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