Gardner Denver FIL Series

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Summary

General Safety Information

Pressurized Devices Safety

Safety precautions for handling pressurized equipment, emphasizing operating pressure limits and depressurization before servicing.

Breathing Air Requirements

Information regarding the suitability of treated air for breathing, referring to OSHA standards for specific requirements.

Flammable Gas Application Limits

Application limitations for flammable gases, including ventilation requirements and use in hazardous environments.

Model Number Configuration

Grade Identification

Details on identifying filter grades by model number digit and element color, listing types and applications.

1.0 Installation

Filter Grade Application Guide

Guidance on selecting filter grades based on application, particle removal, liquid efficiency, and oil content.

Mounting Procedures

Instructions for wall mounting brackets and mounting differential pressure gauges to the filter head.

Piping and Drain Provisions

Piping Installation Guidelines

Instructions for piping installation, including blow-out procedures, thread sealing, flow direction, and modular connections.

Drain Provisions and Connections

Details on internal automatic drains and options for external auto drains, including connection specifics and safety warnings.

2.0 Operation

Liquid Draining Procedures

Instructions for manual and automatic draining of collected liquids from filter grades A, B, C, E, F, emphasizing proper operation.

Operational Checkpoints

Checks for proper installation level, drain function, and liquid level for all grades, with specific checks for Grade G.

Flow Capacity Calculations

Guidance on determining maximum air flow based on pressure and correction factors from provided tables.

3.0 Maintenance

Filter Element Replacement Criteria

Guidelines for when to replace filter elements based on pressure drop, usage hours, or annual replacement.

Element Replacement Procedure

Step-by-step instructions for safely replacing filter elements, including depressurization and handling precautions.

Automatic Drain Mechanism Service

Recommendation for annual replacement of the automatic drain mechanism to ensure proper function.

Dimensions and Weights

Filter Model Specifications

Detailed table of specifications including nominal air flow, connection sizes, dimensions, and weight for various filter models.

Differential Pressure Gauge Diagram

Diagram illustrating the differential pressure gauge and its connection points on the filter.

Warranty Information

Product Warranty Coverage

Details on the one-year limited warranty, exclusions, limitations of liability, and authorization for service.

This document is an instruction manual for Gardner Denver FIL Series Compressed Air Filters, specifically models FIL12 through FIL30. It provides comprehensive information regarding the installation, operation, maintenance, and technical specifications of these filters.

Function Description

The Gardner Denver FIL Series Compressed Air Filters are designed to remove various contaminants from compressed air, including water, oil aerosols, solid particles, and oil vapor. These filters are crucial for ensuring the quality of compressed air in various applications, from general purpose to highly sensitive processes requiring oil-free air. The filters are categorized by "Filter Grade" (A-G), each designed for specific filtration requirements.

Water Separator (Grade A): Primarily removes bulk liquids (water) downstream of an aftercooler or at point-of-use where no aftercooler is installed. It achieves 95% water removal efficiency and can handle up to 30,000 ppm w/w inlet liquid loading.
Separator/Filter (Grade B): Acts as a prefilter to refrigerated dryers or for general separation. It uses a mechanical separator and a 3-micron coalescer, achieving 99+% water removal efficiency and reducing oil content to 5 aerosols ppm w/w.
General Purpose (Grade C): A 1-micron coalescer used as a prefilter for high-efficiency filters (Grade F & E) or at point-of-use where an aftercooler is installed. It offers 100% water removal and reduces oil content to 1 aerosol ppm w/w.
Dry Desiccant Afterfilter (Grade D): A 1-micron afterfilter for desiccant dryers, designed for applications where no liquid should be present at the inlet. It flows from outside to inside of the element, unlike other grades.
High Efficiency Oil Removal Filter (Grade E): A high-efficiency (99.99+%) coalescer used downstream of refrigerated or pressure-swing (heatless) desiccant dryers for finer solid particle and oil removal. It achieves 99.99+% oil removal efficiency, reducing oil content to 0.008 aerosols ppm w/w.
Maximum Efficiency Oil Removal Filter (Grade F): A maximum efficiency (99.999+%) coalescer, serving as a prefilter for desiccant and membrane dryers (after Grade C) or as an afterfilter for refrigerated dryers. It achieves 99.999+% oil removal efficiency, reducing oil content to 0.0008 aerosols ppm w/w.
Oil Vapor Removal Filter (Grade G): An activated carbon adsorber for true oil-free applications, removing vapors only. It reduces oil content to 0.003 vapor ppm w/w and requires no liquid to be present at the inlet.

Important Technical Specifications

Models: FIL12 through FIL30.
Capacity: Ranges from 20 scfm [35 m³/hr] for FIL12 to 780 scfm [1325 m³/hr] for FIL30, at 100 psig [7 kgf/cm²].
Connection Sizes (NPT): Varies from 3/8" for FIL12 to 2-1/2" for FIL28 and FIL30.
Maximum Working Pressure: Housing rated for 300 psig (21.1 kgf/cm²); models with internal drain or liquid level indicator rated for 250 psig (17.6 kgf/cm²).
Maximum Operating Temperature: 150°F (66°C). For Grade G, operation above 100°F (38°C) may reduce element life to less than 1000 hours due to increased oil vapor content. Liquid filtration above 120°F (49°C) is not recommended due to oil vapor condensation.
Materials of Construction:
- Head Material: Zinc (for FIL12-FIL20), Aluminum (for FIL22-FIL30).
- Bowl Material: Aluminum.
- Liquid Level Indicator Material: Isoplast.
Solid Particle Removal: Ranges from 3 microns (Grade B) down to 0.01 microns (Grades E, F, G).
Oil Removal Efficiency: Up to 99.999+% for Grade F.
Correction Factor: An Air Flow Correction Factor table is provided to adjust maximum air flow rates for inlet pressures other than 100 psig.

Usage Features

Model Number Configuration: A clear system for identifying Housing Number, Filter Grade, Connection Size, and Features (Internal Automatic Drain, Differential Pressure Slide Indicator, Differential Pressure Gauge Indicator, Liquid Level Indicator, Corrosion Proof Stainless Steel Element).
Grade Identification: Filter grade is identified by the third digit of the model number and by the outer foam color of the elements (Red for Grade E, Blue for Grade F, Green for Grade G; others are none).
Mounting:
- Wall Mounting Brackets: Provided for secure installation to the filter head.
- Differential Pressure Gauge: Mounts to the filter head with specific instructions for connecting high and low-pressure transmission bolts to the inlet and outlet ports.
Piping:
- Flow Direction: Filters must be installed according to arrows on the filter head. Grade D flows outside-to-inside, all other grades flow inside-to-outside.
- Horizontal Connections: Inlet and outlet connections should be horizontal, and the filter bowl vertical, to ensure proper liquid drainage.
- Modular Connection: Filter heads can be directly joined without pipe nipples using bayonet type or threaded heads with modular connectors and o-rings.
- Isolation Valves and By-pass Piping: Recommended for ease of service and to avoid air supply interruption in critical applications.
Drain Provisions:
- Internal Automatic Drains: Automatically discharge liquids when sufficient accumulation occurs. Can be manually drained.
- External Auto Drains: Adapters are available for connecting external drain lines.
Operational Checkpoints:
- Level Installation: Ensure the filter is installed level for proper drainage.
- Drain Function: Periodically check manual drains and ensure automatic drains are functioning.
- Liquid Level Sight Glass: Verify liquid level is below the top of the sight glass.
- Pressure Drop: Monitor pressure differential across the filter. An increase to 6 psi (0.42 kgf/cm²) or more (red area on indicator) signals element replacement. Sudden reduction in pressure drop may indicate a leak or physical damage.
- Oily Smell (Grade G): An oily smell indicates element exhaustion, leaks, or presence of liquids due to prefilter failure.

Maintenance Features

Element Replacement:
- Frequency: Elements should be changed annually or when the pressure indicator turns red (6 psi / 0.42 kgf/cm² differential pressure). Grade D elements also have an annual replacement recommendation.
- Grade A: Element does not typically require replacement unless physically damaged; it can be removed and cleaned with soap and water if sludge accumulates.
- Grade G: Element life is approximately 1000 hours at rated capacity, or when odor is detected downstream.
- Procedure: Involves isolating the filter, depressurizing, removing the bowl (bayonet mount or threaded), cleaning the bowl, pulling off the old element, and pushing on the new element.
- Handling: Grades E, F, and G elements should be handled by the bottom end cap, not the outside foam cover.
- Lubrication: O-rings must be generously lubricated before installation. Threaded bowl-to-head connections also require high-grade/temperature lubricant.
Auto Drain Mechanism: Recommended to be replaced annually.
Safety: Always depressurize the filter completely before servicing. An audible alarm will sound if the bowl is removed under pressure.
Warranty: One-year warranty from shipment date, covering defects in material and workmanship under normal service conditions. Excludes normal maintenance items and damage from misuse, abuse, neglect, or accident. Repair or replacement is at the manufacturer's sole option.