Beko CLEARPOINT L 205 V, Instructions For Installation And Operation Manual

Page 1: ...EN english Instructions for installation and operation Activated carbon adsorber without dust filter CLEARPOINT L 205 L295 V ...

Page 2: ...er Please read these installation and operating instructions carefully before mounting and starting up the CLEARPOINT V activated carbon adsorber and follow our directions Perfect functioning of the activated carbon adsorber can only be guaranteed when the provisions and notes stipulated here are strictly adhered to ...

Page 3: ...CHNOLOGIES GMBH 41468 Neuss Germany Phone 49 2131 988 0 www beko de Year of construction Type Serial no Max permissible operating pressure PS Working pressure Min max permissible temperature TS Compressed air inlet temperature Max volume flow at the INLET Weight approx Please enter the data from the type plate of the activated carbon adsorber here ...

Page 4: ... carbon adsorber 16 9 Operating principle 17 10 Technical data 18 10 1 Technical data CLEARPOINT L 205 295 V 18 10 2 Available options 20 10 3 Filter selection table 21 11 Description of the components 22 12 Transport and set up 24 12 1 Safety during transport and set up 24 12 2 Transport 24 12 3 Set up 25 13 Installation 26 13 1 Safety during the installation 26 13 2 Minimum requirements 28 13 2 ...

Page 5: ...ing and fault elimination 36 15 2 Status and alarm indications 38 16 Maintenance 40 16 1 Safety during maintenance 40 16 2 Maintenance in general 42 16 3 Maintenance of the CLEARPOINT V activated carbon adsorber 42 16 3 1 Replacement of the activated carbon 43 16 4 Periodic inspections 45 17 Dismantling and disposal 46 18 List of spare parts 47 19 EC Declaration of Conformity 47 ...

Page 6: ...ation and operation with regard to the set up monitoring operation and maintenance of the plant as well as to the safety measures to be observed The operating instructions must be accessible at all times at the place of application of the device Non observance of the installation and operating instructions involves risks for persons and systems If you have any queries regarding these instructions ...

Page 7: ...to life and physical condition or can lead to property damage are labelled in accordance with DIN 4844 and ANSI Z535 4 1 1 Safety pictograms in accordance with DIN 4844 General danger symbol Quickly escaping compressed air Note Observe operating instructions Use eye protection Wear light breathing protection Use protective gloves Wear ear protectors ...

Page 8: ...tial hazard Consequences of non observance possible serious injury or death Caution Imminent hazard Consequences of non observance possibly injury or property damage Notice Potential hazard Consequences of non observance possibly injury or property damage Important Additional advice info hints Consequences of non observance disadvantages during operation and maintenance no danger ...

Page 9: ... be arranged in such a manner that endangering of persons is excluded Where required observe the manufacturer s additional advice Suitable and permissible arming devices need to be provided in accordance with the local regulations The max permissible operating parameters such as the operating overpressure temperature and volume flow must not be exceeded The max permissible operating parameters are...

Page 10: ...sible operating pressure Exceeding the max permissible operating temperature Exceeding the max permissible volume flow All individual cases of application which are described as improper Caution Improper transport Improper transport can lead to injury and damage to plants The CLEARPOINT V must only be transported and installed by qualified and authorised skilled personnel Only use suitable and tec...

Page 11: ...he operational reliability and affect service measures The clear diameter of the pipe joint must be at least as large as the mounting dimension of the CLEARPOINT V It is strongly recommended to install a shut off valve both upstream and downstream of the CLEARPOINT V for the implementation of service measures To maintain the supply of compressed air during service failures maintenance and repair w...

Page 12: ...through quickly or suddenly escaping activated carbon dust Activated carbon can produce dust and wear debris Use eye protection During the start up of the activated carbon adsorber compressed air might escape and cause a very loud expansion noise Wear silencing ear protectors Wear personal protective clothing Wear light breathing protection at strong dust development Caution Activated carbon produ...

Page 13: ...ng from material fatigue the CLEARPOINT V should not be exposed to vibrations during operation The maximum operating pressure indicated by the manufacturer on the type plate must not be exceeded It is the operator s responsibility to install the appropriate safety and control devices Prior to the start up of the CLEARPOINT V the connected pressure generator compressor etc must be safeguarded again...

Page 14: ...tructions carefully prior to any intervention regarding the CLEARPOINT V The operating instructions must be accessible at all times at the place of application of the device If you have any queries regarding these instructions please contact BEKO TECHNOLOGIES GMBH To ensure safe operation the device must only be operated and maintained in accordance with the indications in the operating instructio...

Page 15: ...x permissible operating temperature Exceeding the max permissible volume flow Employment of the CLEARPOINT V in hazardous areas All individual cases of application which are not described as proper us 7 Applied EU directives and harmonised standards Applied EU directives 97 23 EC Pressure Equipment Directive Harmonised standards applied EN 10216 2 Seamless steel tubes for pressure purposes Technic...

Page 16: ...volume flow the exact life expectancy and dimensioning depends on the applied type of oil the compressor type and the humidity of the compressed air The following modifications of the operating conditions may lead to a reduction in the activated carbon adsorber s service life Increase of the volume flow Increase of the operating pressure Increase of the relative humidity of the compressed air Incr...

Page 17: ...essed air distributor and travels top down through the volume filled with activated carbon During this process the activated carbon adsorbs the majority of the oil aerosols and the oil vapour Subsequently the compressed air purified in this manner flows to the outlet through the lower compressed air distributor This process takes place without regeneration phases The activated carbon is thus gradu...

Page 18: ...um operating pressure 4 bar g Max permissible operating overpressure L 205 275 V 16 bar g Max permissible operating overpressure L 295 V 11 bar g Recommended operating pressure 7 bar g Residual oil content at the outlet max 0 003 mg m Adsorbent Activated carbon type 1 Service life at nominal performance data and reference conditions Approx 10 000 operating hours Compressed air connection See table...

Page 19: ... 405 280 21 85 II L 215 V 200 G1 1490 340 340 405 280 21 85 II L 220 V 280 G1 1850 450 450 530 380 42 130 III L 225 V 380 G1 1850 450 450 530 380 42 130 III L 230 V 500 G1 1810 450 450 530 380 57 160 III L 240 V 630 G2 1980 420 560 105 68 200 III L 250 V 800 G2 1940 470 590 105 85 220 III L 260 V 1000 G2 1970 570 700 120 120 260 IV L 275 V 1250 G2 1970 570 700 120 120 260 IV L 295 V 1550 G2 2080 6...

Page 20: ...rbon adsorber will be reduced when these values are exceeded Therefore the employment of a refrigeration or even an adsorption dryer is required upstream of the activated carbon adsorber Please contact our specialist departments to select a suitable compressed air dryer Oil check indicator For the rough assessment of the compressed air quality an oil check indicator can be used The oil check indic...

Page 21: ...07S M010RFWM OF 10F OF L 210 V S075SWTX 07S M012RFWMX OF 12F OF L 215 V M010SWT 10S M015RFWM OF 15F OF L 220 V M015SWT 15S M018RFWM OF 18F OF L 225 V M018SWT 18S M020RFWMX OF 20F OF L 230 V M020SWTX 20S M022RFWMX OF 22F OF L 240 V M022SWT 22S M023RFWM OF 23F OF L 250 V M023SWT 23S M025RFWM OF 25F OF L 260 V M025SWT 25S M027RFWM OF 27F OF L 275 V M025SWT 25S M030RFWMX OF 30F OF L 295 V M027SWT 27S ...

Page 22: ...ARPOINT L 205 L295 V 11 Description of the components 1 Compressed air INLET 2 Filler neck for activated carbon not for L 205 V 3 Container for the activated carbon filling 4 Manometer pressure vessel 5 Base frame 6 Compressed air OUTLET ...

Page 23: ...RPOINT L 205 L295 V 23 1 Compressed air INLET 2 Filler neck for activated carbon 3 Container for the activated carbon filling 4 Manometer pressure vessel 5 Compressed air OUTLET 6 Draining nozzle for activated carbon 7 Inspection access ...

Page 24: ...k the CLEARPOINT V for possible transport damage subsequent to transport and removal of the packaging material The forwarding agent and BEKO TECHNOLOGIES or the BEKO TECHNOLOGIES agency must be informed immediately about any kind of damage If no evident damage to the packaging or the plant was ascertained but hidden defects are detected at a later moment in time the forwarding agent must immediate...

Page 25: ...ant components cannot be transferred This also and particularly concerns the pulsation of the compressed air as otherwise the activated carbon may be destroyed Set up the CLEARPOINT V in such a manner that the plant is easily accessible from the sides For checks of the pressure vessels maintenance and repair measures sufficient free space must be available on all sides at least 1 5 m around the CL...

Page 26: ...nsure that the connected pressure generator is secured against exceeding of the maximum operating overpressure and the temperature limits at the CLEARPOINT V Pressure relief valves used need to be arranged in such a manner that endangering of persons is excluded Where required observe the manufacturer s additional advice Suitable and permissible safety arming devices need to be provided in accorda...

Page 27: ... compromise the operational reliability and affect service measures The clear diameter of the pipe joint must be at least as large as the mounting dimension of the CLEARPOINT V It is strongly recommended to install a shut off valve both upstream and downstream of the CLEARPOINT V for the implementation of service measures To maintain the supply of compressed air during service failures maintenance...

Page 28: ...ilter F with manual drain Particle classification 1 µm 13 2 2 Water content of the compressed air Max permissible residual humidity 30 13 2 3 Inlet temperature of the compressed air Recommended inlet temperature 35 C Non observance of the indicated minimum requirements regarding the installation and permissible operating parameters can lead to drastic reduction of the service life of the CLEARPOIN...

Page 29: ...INT OCV H1 H2 Shut off valves of the measuring section H3 Shut off valve of the bypass H4 Vent valve of the measuring section The depicted installation shows the minimum requirement regarding the installation of a CLEARPOINT V activated carbon adsorber Other types of installation are possible provided that they meet the defined operating conditions For service measures it is recommended to install...

Page 30: ...ves of the measuring section H3 Shut off valve of the bypass H4 Vent valve of the measuring section The depicted installation shows another installation possibility of the CLEARPOINT V activated carbon adsorber that meets the minimum requirements Other types of installation are possible provided that they meet the defined operating conditions For service measures it is recommended to install a byp...

Page 31: ...xample with prefilter afterfilter shut off valves and bypass To install the CLEARPOINT V proceed as follows Ensure that the conditions of use of the CLEARPOINT V are met and that the operation limits are not exceeded Ensure that the system is pressureless prior to integrating the CLEARPOINT V into the compressed air system Prior to installation it must be ensured that all possible contaminations a...

Page 32: ...d skilled personnel Prior to undertaking any measures on the CLEARPOINT V the skilled personnel shall read up on the device by carefully studying the operating instructions The operator is responsible for the adherence to these provisions The respective directives in force apply to the qualification and expertise of the skilled personnel It is the operator s duty to ensure that the connected press...

Page 33: ...otection at strong dust development 14 2 Check prior to the start up As regards the check prior to the start up the country specific provisions need to be observed The plant contains pressure equipment of different categories according to the 97 23 EC Pressure Equipment Directive For this reason it is necessary to register the entire plant with the relevant authority in accordance with the local p...

Page 34: ...ng pressure Filling of the activated carbon adsorber with compressed air during the start up must be implemented as slowly as possible Under no circumstances must the flow rates which correspond to those of the nominal performance data be exceeded Recommended amount of compressed air during the filling of the activated carbon adsorber Pressure build up approx 1 bar min or 1 of the nominal performa...

Page 35: ...4 4 Restart If the CLEARPOINT V is restarted after a longer down time proceed as during the initial start up Check above all after completed maintenance or repair measures whether the CLEARPOINT V is completely tubed If not carry out proper installation 14 5 Removal from service For safety reasons short term removal from service should always be implemented together with the compressor For the rem...

Page 36: ...ions as well as the accident prevention regulations required for the respective case of application need to be observed during employment This applies accordingly when accessories are used Danger Incorrect fault elimination The incorrect fault elimination at the CLEARPOINT V involves the risk of personal injury Ensure that the personnel in charge of the operation supervision and maintenance of the...

Page 37: ...is specified on the type plate and in the technical data see Technical data section Never make structural modifications to the plant Use suitable tools and genuine spare parts and accessories only Only use pipes valves and fittings which are suitable for the pressure and temperature range It is of vital importance to observe the specifications of the manufacturer Check all pipe connections subsequ...

Page 38: ...hausted Pressure difference too high Replace the inlet filter elements Use of oil contaminated filters or filter elements downstream of the activated carbon adsorber Use of BEKO filters and filter elements in an oil and grease free version Oil contaminated circuit sections between the activated carbon adsorber and the measuring point Clean the pipesection or install a new pipesection Condensate dr...

Page 39: ...stem upstream of the activated carbon adsorber is pressureless Check the compressed air system upstream of the activated carbon adsorber Eliminate any faults Larger amounts of wear debris in the system clogged compressed air distributor or filter elements Replace the dust filter element Replace the activated carbon Clean the compressed air distributor Verify the operating conditions pulsation volu...

Page 40: ...dent prevention regulations required for the respective case of application need to be observed during employment This applies accordingly when accessories are used Danger Incorrect maintenance Incorrect maintenance of the CLEARPOINT V involves the risk of personal injury Ensure that the personnel in charge of the operation supervision and repair of the CLEARPOINT V are sufficiently instructed and...

Page 41: ...cifications of the manufacturer Check all pipe connections subsequent to maintenance or repair measures and retighten them if necessary Prior to the restart a leak test needs to be carried out This test shall only be effected by correspondingly qualified skilled personnel in compliance with the safety regulations Caution Activated carbon dust Eyes and respiration are endangered through quickly or ...

Page 42: ...its persons For emergency cases there must be the possibility to cut off the plant section 16 3 Maintenance of the CLEARPOINT V activated carbon adsorber Action daily weekly annually Check the exterior of the plant for contaminations damages and corrosion x Record the current operating parameters and compare them with the indications under Technical data x Check the manometer x Check all pipe conn...

Page 43: ...autions regarding the handling of chemicals need to be taken In the event of fire there are no restrictions regarding the applicable fire extinguishing agents It is recommended to use CO2 powder or a directed spray of water use a directed spray of water or alcohol resistant foam in the event of larger fires Special personal protective equipment for firefighting is not required Spilled activated ca...

Page 44: ...ard and approved for these areas minimum requirement zone 22 Please use conductive accessories only Where flammable vapours or gases exist an additional approval for the gas explosion protection is required Where contamination through toxic harmful mutagenic or mutation promoting components is anticipated suitable filters must additionally be provided As regards the CLEARPOINT L 240 295 V the drai...

Page 45: ... the directions in the Initial start up section 16 4 Periodic inspections The pressure vessel of the CLEARPOINT V activated carbon adsorber must be checked at regular intervals by a technical expert or an authorised expert The determination of the time limits regarding periodic inspections is incumbent on the operator and depending on the classification into the pressure device category in accorda...

Page 46: ...ivated carbon type 2 21 kg L 215 V Activated carbon type 2 21 kg L 220 V Activated carbon type 2 42 kg L 225 V Activated carbon type 2 42 kg L 230 V Activated carbon type 2 57 kg L 240 V Activated carbon type 2 68 kg L 250 V Activated carbon type 2 85 kg L 260 V Activated carbon type 2 120 kg L 275 V Activated carbon type 2 120 kg L 295 V Activated carbon type 2 160 kg Adsorbent The activated carb...

Page 47: ...ber again during maintenance works BEKO Technologies offers the supply of predried activated carbon Type CLEARPOINT V Order no Activated carbon predried Order no Activated carbon undried Order no set compressed air distributor L 205 V 4017088 4017096 4021051 L 210 V 4017089 4017562 4021051 L 215 V 4017089 4017562 4021051 L 220 V 4017090 4017563 4021052 L 225 V 4017090 4017563 4021052 L 230 V 40170...

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