Operating instructions

KFWA BY 1– 4

Fuel Treatment System

Mat. no. operating instructions: 72403726, DIS: 5070-20157768-S00-000-01

Table of contents

© Copyright 2015

Filtration Group GmbH

Tarpenring 31-33
D-22419 Hamburg
Tel.: +49 40 530 040-0
Fax: +49 40 530 040-24191
[email protected]
www.FiltrationGroup.com

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Operating instructions KFWA_BY_1-4_en, Filtration Group GmbH, Issue 03/2017

 Table of contents

Table of contents
1 Introduction ............................................................................................................................................................ 5
1.1 Manufacturer .................................................................................................................................................................. 5
1.2 About these operating instructions ................................................................................................................................. 5
1.3 Typographical conventions ............................................................................................................................................ 6
1.3.1 Safety instructions .............................................................................................................................................. 6
1.3.2 Other instructions................................................................................................................................................ 6
1.4 Abbreviations ................................................................................................................................................................. 6

2 Safety ...................................................................................................................................................................... 7
2.1 Intended use .................................................................................................................................................................. 7
2.2 Qualification ................................................................................................................................................................... 7
2.3 Basic safety instructions ................................................................................................................................................ 7
2.3.1 Blocked evacuation routes.................................................................................................................................. 7
2.3.2 Live components ................................................................................................................................................ 7
2.3.3 Salt- and oil-containing media ............................................................................................................................ 8
2.3.4 Warning and mandatory signs ............................................................................................................................ 8

3 General description ............................................................................................................................................... 9

3.1 Operating principle ......................................................................................................................................................... 9
3.2 Main components......................................................................................................................................................... 10
3.3 Main terminals on the KFWA unit................................................................................................................................. 11
3.4 Flow chart .................................................................................................................................................................... 12

4 System control ..................................................................................................................................................... 13

4.1 Controls and indicator lamps on the control cabinet .................................................................................................... 13
4.2 Switching on/starting on the system............................................................................................................................. 14
4.3 Settings (factory settings) for electrical components .................................................................................................... 14

5 Assembly .............................................................................................................................................................. 15
5.1 Setup ........................................................................................................................................................................... 15
5.2 Assembly and disassembly of the piping ..................................................................................................................... 15
5.3 Electrical connection .................................................................................................................................................... 15

6 Inspection and preparation for start-up ............................................................................................................ 16

6.1 General preparations ................................................................................................................................................... 16
6.2 Checking the differential pressure contact switch ........................................................................................................ 17
6.3 Checking water discharge ............................................................................................................................................ 17
6.4 Checking the level probe ............................................................................................................................................. 18
6.5 Checking the pump ...................................................................................................................................................... 19
6.5.1 Checking pump pressure .................................................................................................................................. 20
6.5.2 Checking the pressre in throttled state......................................................................................................................... 21
6.5.3 Calculating the wear limit .................................................................................................................................. 21
6.6 Filling the system ......................................................................................................................................................... 23

7 Start-up, operation and monitoring operations................................................................................................ 24

7.1 Starting filtration ........................................................................................................................................................... 24
7.2 Checks during operation .............................................................................................................................................. 25
7.3 Operation with a soiled filter/coalescer element ........................................................................................................... 25
7.4 Taking the system out of service.................................................................................................................................. 25
7.4.1 Shutting down the system temporarily or in an emergency .............................................................................. 25

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Table of contents

7.4.2 Shutting down the system for a prolonged period (more than 48 hrs) .............................................................. 25

8 Maintenance and servicing ................................................................................................................................. 26

8.1 Prior to commencing maintenance work ...................................................................................................................... 26
8.2 Maintenance schedule ................................................................................................................................................. 27
8.3 Cleaning the dirt trap on the pump ............................................................................................................................... 27
8.4 Replacing the filter/coalescer element ......................................................................................................................... 28

9 Troubleshooting .................................................................................................................................................. 30
9.1 Troubleshooting chart .................................................................................................................................................. 30

10 Technical data ...................................................................................................................................................... 31

11 Recommended spare parts ................................................................................................................................ 32

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 1 Introduction

1 Introduction

1.1 Manufacturer

Filtration Group GmbH

Tarpenring 31-33
D-22419 Hamburg
Phone: +49 (0) 40 530040 0
Fax: +49 40 530040 24191

1.2 About these operating instructions

These operating instructions are intended to help the operator make optimum use of the system. If
you refer to all of the instructions, you can avoid potential dangers and extend the life of the system.
These operating instructions are to assist personnel with special technical knowledge for operating
the system. If you have any further questions on the content of the operating instructions or opera-
tion of the system, please contact the manufacturer.
These operating instructions are included with the system. Read the operating instructions com-
pletely before putting the system into operation. Each person who works on and with the system
must have read and understood the operating instructions beforehand.
Always keep these operating instructions available on site. Enclosed instructions for use from man-
ufacturers of components are part of the operating instructions for the system. Further information
on individual components such as pumps and measuring devices can be found in the correspond-
ing instructions for use supplied by the relevant manufacturers.

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1 Introduction

1.3 Typographical conventions

1.3.1 Safety instructions

In these operating instructions four signal words are used to indicate different hazard severities.

Type of Hazard
 Describes the consequences of the hazard. The consequences will be severe or fatal inju-
ry.
• Specifies the steps that must be taken to avoid the hazard.

Type of Hazard
 Describes the consequences of the hazard. The consequences may be severe injury to
death.
• Specifies the steps that must be taken to avoid the hazard.

Type of Hazard
 Describes the consequences of the hazard. The consequences may be minor injury.
• Specifies the steps that must be taken to avoid the hazard.

Type of Hazard
 Describes the consequences of the hazard. The consequences may be material damage.
• Specifies the steps that must be taken to avoid the hazard.

1.3.2 Other instructions

In these operating instructions, additional information is indicated by a separate symbol.

Provides additional information regarding the system or its operation.

1.4 Abbreviations

BMK Device tags

IBC Intermediate Bulk Container (reusable industrial container)
KFWA Fuel filter water separator, this fuel treatment system

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 2 Safety

2 Safety

2.1 Intended use

The KFWA fuel treatment system is a system for automatically processing fuel. The system is in-
tended for fuel filtration and subsequent water separation.
The system may only be operated in accordance with order-specific performance data. Only
properly installed original spare parts may be used.
All other applications, unauthorised modifications or modes of operation as well as changes to the
system's hardware or software are considered contrary to the intended use and may result in im-
pairment of operational safety and void the warranty.

2.2 Qualification

The system may only be operated by qualified, experienced persons authorized by the owner. Spe-
cialist knowledge must be obtained through regular training.

2.3 Basic safety instructions

Safety instructions are for the purpose of work safety and accident prevention.
To protect personnel from harm, all work on the system must be carried out attentively and with
care.
Please also refer to the safety regulations of the owner and the regulations applicable in the area in
which the system is operated.

2.3.1 Blocked evacuation routes

Blocked evacuation routes and inaccessible working areas could cause serious injury or material
damage.
• Keep the working area free and accessible at all times.
• Never place objects in the working area.
• Ensure that no objects can fall or topple onto lines.

2.3.2 Live components

After an EMERGENCY STOP, certain components in the control cabinet are still live. Contact with
these components can lead to fatal or serious injury.
• Keep the control cabinet closed.
• In case of malfunctions, call in an electrician or contact the manufacturer.

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2 Safety

2.3.3 Salt- and oil-containing media

The collected medium and operating or cleaning fluids flowing out can cause environmental dam-
age and irritation of the skin upon contact.
• Keep a suitable tank at hand to catch residues and flushing quantities.
• Refer to product-specific safety regulations and datasheets.
• Wear protective clothing where necessary.

2.3.4 Warning and mandatory signs

Hazard from electrical power

Note on danger to water

Wear protective clothing

Wear safety gloves

Wear safety goggles

Wear respiratory protection

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 3 General description

3 General description

3.1 Operating principle

The KFWA fuel treatment system is a filter coalescer system. The fuel is pumped by a gear pump
from the inside to the outside through the coalescer element. The fuel first flows through the filter
layer and then the coalescing layer, where the water is separated. To separate the water, various
hydrophilic materials are incorporated into the coalescing element, which are able to retain very
small water droplets. After a certain time, the small water droplets combine into large drops of ap-
prox. 3 mm , which emerge from the element and sink to the bottom of the tank.
The accumulation of water is monitored by a level probe and emptied through the automatic water
drain valve when the maximum level is reached. The water drain valve opens and closes automati-
cally during ongoing operation of the system. No subsequent venting of the KFWA is necessary.
Contamination of the filter/coalescing element is monitored via differential pressure. When differen-
tial pressure reaches the value set for for the pre-alarm, a warning alert to this effect appears. If dif-
ferential pressure rises to the value set for the main alarm, another warning alert appears and the
element must be replaced immediately. If the element is not replaced, pressure will continue to rise
up to the predefined pressure at which the overflow valve opens. In this situation, the fuel is
pumped to the tank without being cleaned.

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3 General description

3.2 Main components

Fig. 1 Main components of the KFWA

Item Component
1 Splash guard
2 KFWA pressure tank with filter/coalescer elements
3 Differential pressure gauge, switch with 2 contacts for pre and main alarm
4 Control unit (control cabinet), with controls
5 Fuel pump, gear pump with electric motor, included separately
6 Shut-off valve

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 3 General description

3.3 Main terminals on the KFWA unit

Fig. 2 Main terminals on the KFWA unit

Item Description
F1 Inlet
F2 Water drain
F3 Drain
F4 Vent/sampling point outlet
F5 Outlet
F6 Sampling inlet

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3 General description

3.4 Flow chart

Fig. 3 KFWA flow chart

Item Description
A Customer-supplied bunker tank
B Customer-supplied prime mover
C Customer-supplied overflow
1 Fuel pump
2 2-stage filter water separator
3 Level probe (water level electrode)
4 Pressure gauge and ball valve
5 Ball drain valve
6 Dirt trap
7 Automatic water drain
8 Disco check valve (700 mbar ±15%)
9 Venting ball valve
10 Overflow valve, 3 bar
11 Control unit (control cabinet)
12 Differential pressure gauge
13 Ball valve (KFWA inlet)
14 Ball valve (KFWA outlet)
15 Sampling

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 4 System control

4 System control

The system control is programmed and set by Filtration Group GmbH. No custo-
mer-side settings can be made or changed.

4.1 Controls and indicator lamps on the control cabinet

Fig. 4 Controls on the control cabinet

Item Element Paint Function

1 Indicator lamp Green Indicates "Pump operation"
2 Indicator lamp Red Indicates "Pump malfunction"
Illuminated push- Indicates/activates "Water discharge"
3 Yellow
button
Illuminated push- Indicates/resets "Water alarm"
4 red
button
5 Indicator lamp Yellow Indicates "Differential pressure pre-alarm"
Illuminated push- Indicates/Acknowledges "Change element"
6 red
button
Operating hours coun- Pump operating hours
7 —
ter
8 Main Switch — Switches the system on/off
9 Indicator lamp White Indicates "Control voltage"
10 Selection switch — Indicates "Off/On"

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4 System control

4.2 Switching on/starting on the system

• Prior to switching on control voltage, make sure that the selector switch for operating mode Fig.
4 (10) is set to "Off".
• Switch on the system from from main switch Fig. 4 (8). The "Control voltage" indicator lamp
Fig. 4 (9) must go on.
• Turn selector switch Fig. 4 (10) to "On" position to start the system. The fuel pump Fig. 1 (5)
starts.

4.3 Settings (factory settings) for electrical components

BMK in
accord-
Component ance with Function Setting value
wiring
diagram
75 kΩ
Electrode relay 2A1 Interface measurement
(500 kΩ/15%)
Time delay relay 2KT1 Max. drain valve opening time 3 minutes
Time delay relay 2KT2 Differential pressure alarm delay 1 minute
Differential pressure warning (pre-
Differential pressure 1.8 bar
2B2 alarm)
switch
Differential pressure alarm (main alarm) 2.0 bar

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 5 Assembly

5 Assembly

Prior to assembly, the system must be inspected for damage and the proper seating
of all installed and mounted parts. All systems have been subjected to a comprehen-
sive factory test, but parts may have become loose during transport however.

Danger from unauthorised installation of the system

 Risk of injury.
 Voiding of the warranty.
• The system may only be installed by specialists.

5.1 Setup

• Mount the KFWA on the wall.

• For wall installation take into account the space (servicing room) required for operating and
maintenance personnel (see overview drawing in the Appendix).
• Attach/mount fuel pump to a suitable place.
• Install connecting piping for all interfaces according to overview drawing and flow chart diagram
(see Appendix).

5.2 Assembly and disassembly of the piping

Pressure at interfaces
 Personal injury or material damage.
• Depressurise all interfaces of the system prior to assembly or disassembly.

• Secure the drain line.

• Do not drain medium out into the open.
• Provide spray guard if required.
• Lay piping at inlet without siphon if possible. Risk of clogging from sedimentary medium!

5.3 Electrical connection

Danger of electric shock

 Fatal or serious injury from touching live components.
• Electrical installations may only be carried out by authorised electricians.

The required electrical supply is centrally located in the control cabinet. Connect the control cabinet
according to the wiring diagram.

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6 Inspection and preparation for start-up

6 Inspection and preparation for start-up

Hazard when exceeding permissible operating pressure

 Death or serious injury may result from exceeding the permissible operating pressure of 6 bar.
• Upon reaching the maximum operating pressure of 6 bar the feed pump must be switched off
immediately.
• Do not allow the medium to spray out into the open.

Pressure in the tank

 Personal injury or material damage.
• Where necessary, only slowly activate venting and discharge ball valves in operation (outlet
pressure 0.7 bar).
• Take necessary safety precautions (put on safety goggles and protective clothing).

6.1 General preparations

• Check vacuum line for dirt and foreign bodies and clean if necessary.
• Check piping connections and tighten if necessary.
• Tighten all screws.
• Close all drain valves on the enclosure.
• Open all intake and outlet valves.
• Open ball valve for the differential pressure contact gauge on intake and outlet connections.

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 6 Inspection and preparation for start-up

6.2 Checking the differential pressure contact switch

Fig. 5 Differential pressure contact switch

1. Set selector switch Fig. 4 (10) to "Off" position.

2. Switch on system from main switch Fig. 4 (8).
3. Turn contact 1 to differential pressure "0".
 Contact switch switches after expiry of the pre-set delay time (factory setting 1 minute).
 An alarm message appears on the control cabinet. (pre-alarm).
4. Turn contact 1 to target value.

If a second contact is present:

5. Turn contact 2 to differential pressure "0".
 Contact switch switches after expiry of the pre-set delay time (factory setting 1 minute).
 An alarm message appears on the control cabinet.
6. Turn contact 2 to target value.

 The differential pressure contact switch is set.

6.3 Checking water discharge

1. Set selector switch Fig. 4 (10) to "Off" position.

2. Switch on the system from the main switch Fig. 4 (8).
3. Press and hold the "Water discharge" illuminated pushbutton Fig. 4 (3).
 Open the discharge valve.
4. Release the illuminated pushbutton.
 The discharge valve closes.

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6 Inspection and preparation for start-up

6.4 Checking the level probe

The level probe may only be checked when the system is at a complete stop.

Pressure in the tank

 Personal injury or material damage.
• Where necessary, only slowly actuate venting and discharge ball valves while testing (outlet
pressure 0.7 bar).
• Take necessary safety precautions (put on safety goggles and protective clothing).

1. Close the ball valves at inlet and outlet of the system.

2. Switch off the system from the main switch Fig. 4 (8).
3. Drain the system via the drain cock.

Fig. 6 Level probe: Remove connector

4. Remove connector 1 on level probe 2.

5. Unscrew the level probe from the enclosure and reconnect it with the connector.
6. Make sure that the selector switch Fig. 4 (10) is in "Off" position.
7. Switch on the system from the main switch Fig. 4 (8).

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 6 Inspection and preparation for start-up

Fig. 7 Immersing the level probe

8. Immerse the level probe up to the threading in a container filled with water (Fig. 7).
9. After being immersed, the water drain must automatically activate and open the water dis-
charge valve. Leave the level probe in the container to trigger the water alarm.
10. An alarm must ensue on the control after the predefined time (factory setting 3 minutes).

6.5 Checking the pump

The functional test of the pump is used to determine the wear limit. If wear and tear has been
found, the pump should be immediately overhauled.

The pump may only be checked when the system is at a complete stop.

Pressure in the tank

 Personal injury or material damage.
• Where necessary, only slowly actuate venting and discharge ball valves while testing (outlet
pressure 0.7 bar).
• Take necessary safety precautions (put on safety goggles and protective clothing).

On the vacuum side the customer must provide on connector P4 (½“) a fine pressure
gauge (Fig. 8) that is removed after the test. The test of the gauge takes place at the
intake of the KFWA enclosure on the pressure side.

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6 Inspection and preparation for start-up

Fig. 8 P4 connection - customer supplied installation of a fine pressure gauge

6.5.1 Checking pump pressure

1. Switch on the system, see Chapter 4.2 Switching on/starting on the system.
2. Slowly close ball valve F5 at the outlet of the KFWA, read and take note of the pressure on the
gauge.

Fig. 9 Excerpt from flow chart

Closing ball valve F5 may activate the pressure control valve on the pump. Any nois-
es are cause by overflowing fuel and may be ignored.

3. Leave the system switched on and check the pressure as described in the following chapter.

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 6 Inspection and preparation for start-up

6.5.2 Checking the pressre in throttled state

1. Throttle the pump unit vacuum line creating a vacuum of 0.8 bar on the vacuum side of the
pump.
2. Again read and note down the pressure from the gauge on the pressure side of the pump.
3. Open ball valves F1 (on inlet of the KFWA) and F5 (on outlet of the KFWA).

Fig. 10 Excerpt from flow chart

6.5.3 Calculating the wear limit

If the pressure found in Chapter 6.5.1 is 10% lower than the pressure found in Chap-
ter 6.5.2, the wear limit of the pump has been reached. The pump should be over-
hauled immediately.

Sample calculation
• Pressure of 3 bar is found on the pressure side (see Chapter 6.5.1 Checking pump
pressure).
• After throttling to -0.8 bar on the vacuum side, pressure of 2.6 bar is measured on the pressure
side (see Chapter

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6 Inspection and preparation for start-up

• 6.5.2 Checking the pressre in throttled state).

Wear limit calculation: 3 bar – (0.1 x 3 bar) = 2.7 bar
• The pressure of 2.6 bar measured in Chapter 6.5.2 is more than 10% below the calculated wear
limit of 2.7 bar. The pump must be overhauled.

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 6 Inspection and preparation for start-up

6.6 Filling the system

Prior to initial start-up and following maintenance work, the system must first be filled and ventilat-
ed.

1. Switch on the system (see Chapter 4.2 Switching on/starting on the system).
2. Activate the fuel pump and check the direction of rotation.
3. Check the operating pressure on the pressure gauge.
4. During operation, carefully vent via ball valve F4.
5. Close ball valve F1 to vent the bypass line. The bypass line is vented via the service tank.
6. Open ball valve F1 again.

Fig. 11 Excerpt from flow chart

7. Check differential pressure.

Initial differential pressure should not exceed 0.3 bar. The temperature and viscosity
of the medium must otherwise be checked.
If during initial operation or after replacing an element the differential pressure gauge
does not show any differential pressure this may be an indication of a bypass within
the system. In this event, check that the element in the KFWA is properly seated and
attached.

8. Check the system for leaks

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7 Start-up, operation and monitoring operations

7 Start-up, operation and monitoring operations

Carry out the preparations in Chapter 6 prior to initial start-up.

Hazard when exceeding permissible operating pressure

 Death or serious injury may result from exceeding the permissible operating pressure of 6 bar.
• When the max. permissible operating pressure of 6 bar is reached the feed pump must be im-
mediately deactivated on the customer side.
• Do not allow the medium to spray out into the open.

Pressure in the tank

 Personal injury or material damage.
• Where necessary, only slowly activate venting and discharge ball valves in operation (outlet
pressure 0.7 bar).
• Take necessary safety precautions (put on safety goggles and protective clothing).

7.1 Starting filtration

Prior to the start of filtration, open all customer-provided fittings in the inlet and outlet
lines.

1. Prior to switching on control voltage, make sure that the selector switch Fig. 4 (10) for operating
mode is set to "Off".
2. Switch on the system from the main switch Fig. 4 (8). The "Control voltage" indicator lamp Fig. 4
(9) must go on.
3. Turn selector switch Fig. 4 (10) to "On" position.
→ The fuel pump starts. The fuel flows through the system and is filtered.

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 7 Start-up, operation and monitoring operations

7.2 Checks during operation

No special monitoring is required during operation. Only the indicator lamps on the control cabinet
(Fig. 4) have to be monitored and any alarms have to be responded to.
However, the following checks must be performed on a daily basis:
• Operating and differential pressure
• Leak integrity of the system
• "Water drain" function

7.3 Operation with a soiled filter/coalescer element

If the filter/coalescer element is soiled, differential pressure will rise above the predefined value and
an alarm message will ensue. If the element is not replaced, pressure will continue to rise until the
overflow valve Fig. 3 (10) on the bypass opens.
The fuel now flows into the bypass, past the KFWA, and into the service tank and the motor-side fil-
ters take over filtration. Water will no longer be separated from the fuel.

7.4 Taking the system out of service

7.4.1 Shutting down the system temporarily or in an emergency

1. Stop Filtration mode: turn selector switch (Fig. 4) (10) to "Off" position.
→ The fuel pump stops.
2. Switch on the system from the main switch Fig. 4 (8).

7.4.2 Shutting down the system for a prolonged period (more than 48 hrs)

1. Stop Filtration mode: Turn selector switch Fig. 4 (10) to "Off" position.
→ The fuel pump stops.
2. Switch off the system from the main switch Fig. 4 (10).
3. Close the ball valves at the inlet and outlet of the system.
4. Check system pressure and reduce it if necessary via the drain.

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Operating instructions KFWA_BY_1-4_en, Filtration Group GmbH, Issue 03/2017

8 Maintenance and servicing

8 Maintenance and servicing

Danger due to unauthorised maintenance work on the system

 Risk of injury.
 Voiding of the warranty.
• The system may only be maintained by specialists.

Pressure in the tank

 Personal injury or material damage.
• Where necessary, only slowly actuate vent and drain ball valves during maintenance (outlet
pressure 0.7 bar).
• Take necessary safety precautions (put on safety goggles and protective clothing).

8.1 Prior to commencing maintenance work

• Shut down the system, see Chapter 7.4 Taking the system out of service.
• Secure the system from being switched on without authorisation.

• Take the necessary safety precautions (protective clothing, safety goggles).

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 8 Maintenance and servicing

8.2 Maintenance schedule

The maintenance schedule depends on the specific use case. Check with Filtration
Group GmbH for details.

Component Interval Measure Comment

Inspect for leaks; check dif-
System Visual inspection
Daily ferential pressure
Water discharge valve Check Ensure proper working order
∆p pressure gauge Monthly Check Ensure proper working order
Dirt trap on the pump If necessary Cleaning See Chapter 8.3
Annually or from
Coalescer Replace the element See Chapter 8.4
∆p ≥ 2.0 bar

8.3 Cleaning the dirt trap on the pump

The dirt trap on the pump may only be replaced with the system is at a complete
stop.

Pressure in the tank

 Personal injury or material damage.
• Where necessary, only slowly actuate venting and discharge ball valves while testing (outlet
pressure 0.7 bar).
• Take necessary safety precautions (put on safety goggles and protective clothing).

1. Close the owner-provided intake in front of the pump's dirt trap.

2. Close ball valves F1 on the inlet and F5 on the outlet.

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8 Maintenance and servicing

3. Loosen the four bolts 1 on the cover of the dirt trap and remove the cover.

Fig. 12 Dirt trap on the pump

4. Remove and clean the now accessible strainer from the dirt trap.
5. Insert the strainer into the dirt trap again and re-tighten the four bolts 1.

8.4 Replacing the filter/coalescer element

The filter/coalescer element may only be replaced when the system is at a complete
stop.

Pressure in the tank

 Personal injury or material damage.
• Where necessary, only slowly actuate venting and discharge ball valves while testing (outlet
pressure 0.7 bar).
• Take necessary safety precautions (put on safety goggles and protective clothing).

1. Close ball valves F1 on the inlet and F5 on the outlet.

2. Open drain F2 and wait until the system is empty.

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 8 Maintenance and servicing

3. Unscrew the nuts 2 on the tank cover. Remove the nuts, bolts 3 and washers and remove the
tank cover.

Fig. 13 Removing the tank cover

4. Remove the cover seal Fig. 13 (1) . The filter/coalescer element is now accessible.
5. Check the seal surfaces on the tank and cover and clean if necessary.
6. Remove the fixing nuts 4, sealing washers 8 and end plates 6 from the element.

Fig. 14 Replacing the filter/coalescer element

7. Remove element 7 from the threaded rod 5.

8. Check KFWA housing for contamination and clean if necessary.
9. Insert a new element. Perform steps 3–7 in reverse order. When inserting the new element in
the tank, make sure that the element is not tilted. Inspect the KFWA housing before assembly
for any assembly residues and clean if necessary.

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9 Troubleshooting

9 Troubleshooting
Major malfunctions are indicated by the indicator lamps on the system's control cabinet (see Chap-
ter 4.1 Controls and indicator lamps on the control cabinet).
• If an alarm message appears, find the components causing the malfunction and remedy it.
• Note (write) down the malfunction and specifically check during subsequent inspections
• If the cause of the malfunction cannot be found and/or it cannot be remedied, contact Filtration
Group GmbH.

9.1 Troubleshooting chart

Fault/malfunction Possible cause Measure

Check KFWA element for proper
Water in the fuel Bypass on the element
seating and correct if necessary.
Check the voltage supply and re-
No power supply
establish if necessary.
Pump not working Check pump for dry running or block-
Activate motor protection age. Reset the motor protection
switch.
Clean the dirt trap, see Chapter 8.3
Insufficient pump vacu-
Dirt trap clogged Cleaning the dirt trap on the
um capacity
pump.
Replace the element,
Differential pressure
Element soiled see Section 8.3 Cleaning the dirt
exceeded
trap on the pump.

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Operating instructions KFWA_BY_1-4_en, Filtration Group GmbH, Issue 03/2017

 10 Technical data

10 Technical data

KFWA MAIN 1 KFWA MAIN 2 KFWA MAIN 3 KFWA MAIN 4

Diesel fuel acc. to EN590, ASTM D975 1D&2D, BS2869
Fuel oil acc. To DIN 51603-1
Marine diesel fuel (MGO, MDO) acc. to
Medium ISO 8217 (DMX, DMA, DMZ, DMC)
Nato fuel F75, F76 acc. to
TL-9140-0003, 8; DEFSTAN 91-4, 7
Diesel fuel with low sulfur content (15ppm)
Viscosity 2-13 [cSt at 40 °C]
Water content: inlet max. 1000 ppm

Mean water separation efficiency Insert Insert Insert

(mean drop size / starting water content) FC-001-030-19 FC-001-040-PS 10 FC-001-040-19
60µm / 1500ppm: ≥95% ≥98% ≥99%
300µm / 1500ppm: ≥97% ≥98% ≥99%
60µm / 20000ppm: ≥85% ≥97% ≥96%

Flow rate max. 800 l/h max. 2200 l/h max. 4400 l/h max. 8000 l/h
Operating temperature min. 2 °C to max. 45 °C
Ambient temperature max. 55 °C
Pre-alarm: 1,8 bar; Main alarm: 2,0 bar (see 4.3 Settings (facto-
Differential pressure alarm value
ry settings) for electrical components 4.3)
Maximum permissible operating pressure 6 bar
Minimum operating pressure 0.7 bar
Pressure loss Max. 2.7 bar
Electrical connection 400 V / 50 Hz or 440 V / 60 Hz
Control voltage 24 VAC
Pressure tank:
Design operating pressure 6 bar
Test pressure 9 bar
Materials:
Frame Sandblasted 2½, coated
Piping Sandblasted 2½, coated
Tank exterior Sandblasted 2½, coated
Tank interior Sandblasted SA 2½
Pump:
Flow rate ca. 670 l/h ca. 2000 l/h ca. 4400 l/h ca. 8000 l/h
Vacuum head max. 2 m
Discharge head min. 3 m
Overflow valve opening pressure 3 bar

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Operating instructions KFWA_BY_1-4_en, Filtration Group GmbH, Issue 03/2017

11 Recommended spare parts

11 Recommended spare parts

Please contact MTU service for spare parts inquiry and order.

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Operating instructions KFWA_BY_1-4_en, Filtration Group GmbH, Issue 03/2017

Filtration Group GmbH
Tarpenring 31-33
D-22419 Hamburg
Tel.: +49 40 530 040-0
Fax: +49 40 530 040-24191
[email protected]
www.FiltrationGroup.com