Beko METPOINT OCV, Installation And Operation Manual

Page 1: ...EN english Instructions for installation and operation METPOINT OCV Oil vapour measuring device with sampling probe 10 017 ...

Page 2: ...fo it beko de 日本 Japan BEKO TECHNOLOGIES K K KEIHIN THINK 8 Floor 1 1 Minamiwatarida machi Kawasaki ku Kawasaki shi JP 210 0855 Tel 81 44 328 76 01 info beko technologies co jp Benelux BEKO TECHNOLOGIES B V Veenen 12 NL 4703 RB Roosendaal Tel 31 165 320 300 info beko nl Polska Poland BEKO TECHNOLOGIES Sp z o o ul Chłapowskiego 47 PL 02 787 Warszawa Tel 48 0 22 855 30 95 info pl beko de Scandinavia...

Page 3: ...otection classification Class I PE Connection G3 8 Female ISO 228 Type of Gas Compressed Air Max working pressure PS 16 bar g Max working temperature TS 55 C Ambient temperature 5 C 45 C Type 4013362 S N 110229435 B0704809 07018 B S139 BEKO TECHNOLOGIES http www beko de B Please enter the serial number S N from the type plate of the sensor unit here 1 2 Evaluation unit with user interface display ...

Page 4: ...he device 16 6 6 Adjusted operating pressure 17 7 System and functional description 18 8 Transport and storage 19 9 Unpacking 19 10 Installation 20 10 1 Place of installation 20 10 2 Installation diagram METPOINT OCV with activated carbon adsorber 22 10 3 Installation diagram METPOINT OCV with BEKOKAT 23 10 4 Installation diagram METPOINT OCV with oil free compression 24 10 5 Installation of METPO...

Page 5: ...f the alarm message 54 13 5 1 Potential free alarm contact 54 13 5 2 Analogue output 4 20 mA 60 13 6 Reading out of the measured values via the Ethernet connection 65 14 Declaration of conformity 66 15 Maintenance and service 68 15 1 Care 68 15 2 Daily check 68 15 3 Calibration 69 15 4 Support with regard to any application queries 69 16 Appendix 70 ...

Page 6: ...increase of the residual oil content values When the system is rendered pressureless measurement is impossible An alarm is indicated Due to continuous technical development we reserve the right to implement necessary modifications without prior notice If you have any queries regarding these instructions please contact BEKO TECHNOLOGIES GMBH This symbol stands for actions which can also be implemen...

Page 7: ...or to connect the protective conductor according to the regulations Do not use plug adapters at the power plug Have the power plug replaced by qualified persons if required WARNING Unauthorised interventions Any modification of the measuring device or of the function parameters which has not been checked and approved by the manufacturer leads to the development of potential danger sources WARNING ...

Page 8: ...structions 8 METPOINT OCV WARNING Unauthorised intervention Unauthorised interventions may endanger persons or plants and lead to malfunction Do not open the housing of the sensor unit or of the evaluation unit ...

Page 9: ... must be kept safe for future reference No objects whatsoever must be installed at or placed on the METPOINT OCV and the connecting lines WARNING Unauthorised intervention Unauthorised interventions may endanger persons or plants and lead to malfunction Tampering modification and abuse of the pressure devices is forbidden Users of the devices need to observe the local and national pressure equipme...

Page 10: ...e METPOINT OCV The METPOINT OCV devices serve for the stationary measurement and monitoring of the vaporous and gaseous residual oil content in compressed air ISO 8573 2001 Any other use is considered improper The manufacturer shall not be liable for the consequences of improper use the user alone is responsible for all risks that may arise The proper employment and use of the METPOINT OCV accordi...

Page 11: ...f application and proper use of the METPOINT OCV METPOINT OCV 11 The METPOINT OCV measuring devices must only be used by qualified and authorised personnel and exclusively in accordance with the technical data ...

Page 12: ...ated to 1 0 bar absolute and 20 C expanded The amount of measuring gas depends on the operating pressure NOTE The measuring gas is released into the environment Please consider the resulting concentration values at the place of installation of the METPOINT OCV Ensure sufficient ventilation Fields of application Downstream of an activated carbon filter see installation instructions Chapter 10 5 Dow...

Page 13: ...s Potential free change over contact 230V AC 5A or 24V DC 5A optional 4 20 mA Power supply Version 1 230 V AC 50 Hz 10 Version 2 115 V AC 60 Hz 10 Internal fusing 1 0 A slow T1A 250V Max operating current Max 0 22 A Power consumption Max 50 6 VA Memory 2 GB internal memory 6 3 EU directives and harmonised standards applied 2006 95 EC Low Voltage Directive 2004 108 EC Directive about the electromag...

Page 14: ...raulic diameters 3 x DN In addition the pipe section must have a constant shape and a constant cross section Inlet zone 10 x DN min 200 mm in accordance with ISO 8573 2 Outlet zone 3 x DN min 100 mm in accordance with ISO 8573 2 For the measuring sections made by BEKO TECHNOLOGIES or for measuring sections which are manufactured according to the specifications of BEKO TECHNOLOGIES we recommend gui...

Page 15: ...e dimensioning of the mounting holes in the Appendix Please make sure to observe the servicing height when choosing the place of installation Servicing height with probe type 1 500 mm Servicing height with probe type 2 700 mm 6 4 2 Evaluation unit with user interface ...

Page 16: ...y cable for the sensor unit 9 Power supply cable for the evaluation unit 10 Signalling cable 11 Connection signalling cable sensor unit 12 Connection signalling cable evaluation unit 13 On off switch incl indicator green LED 14 Connection analogue output 4 20 mA see Chapter 13 5 2 page 60 15 Connection Ethernet 16 Measuring gas connection M 19 Connection potential free alarm contact see Chapter 13...

Page 17: ...OCV has been prepared and adjusted to the operating pressure indicated by you You will find this setting below the type plate of the sensor unit Please contact us in the event that your operating conditions have changed The BEKO service team will then adjust your device correspondingly EINGESTELLTER ARBEITSDRUCK ADJUSTED WORKING PRESSURE PRESSION REGLÉE À 7 5 bar g ...

Page 18: ...signalling cable with a length of 5 m the sensor unit is connected with the evaluation unit The sampling probe is installed centrically from the top in the rising main so that the probe takes compressed air in the centre of the compressed air flow to be monitored The sensor of the METPOINT OCV functions according to the proven and reliable principle of photoionisation The measuring principle of a ...

Page 19: ...installation and operating instructions should be kept with the device 9 Unpacking After having checked the soundness of the outer packaging set up and unpack the device in close proximity to the selected places of installation of the sensor and the evaluation unit For the connection to the sensor unit do not touch the probe without wearing oil and grease free gloves textile gloves are recommended...

Page 20: ... used 10 1 Place of installation CAUTION Ambient conditions Choose a place of installation which cannot impair the specified function of the METPOINT OCV Installation in ambient conditions which are not suitable affects the measuring results and can lead to malfunctions and damage to the sensor The device must not be operated in an explosive environment or in areas with high fire danger near aggre...

Page 21: ...nd grease free dimensions in accordance with the BEKO provisions inflow towards the probe from the bottom to the top see flow direction The measuring section must be installed vertically The employment of an original BEKO measuring section is recommended The installation of a bypass see Chapter 10 5 or of a ball valve between the sensor unit and the measuring section is recommended Ambient tempera...

Page 22: ...ing section H3 Shut off valve of the bypass H4 Vent valve of the measuring section The depicted installation shows the minimum requirement of the METPOINT OCV in combination with an 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 a bypass at the METPOINT OCV This applies ge...

Page 23: ...ff 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 of the METPOINT OCV in combination with a BEKOKAT Other types of installation are possible provided that they meet the defined operating conditions For service measures it is recommended to install a bypass at the METPOINT OCV This applie...

Page 24: ...bypass H4 Vent valve of the measuring section The depicted installation shows the minimum requirement of the METPOINT OCV in combination with a compressor with oil free compression Other types of installation are possible provided that they meet the defined operating conditions For service measures it is recommended to install a bypass at the METPOINT OCV This applies generally to all components t...

Page 25: ...sured values should be carried out at an interval which is adapted to the shorter maintenance interval of the activated carbon filter This installation variant also requires the compliance with the specifications of Chapter 9 1 CAUTION Contaminated input air inferior operating conditions When employing the METPOINT OCV under inferior operating conditions the device can be contaminated damaged or d...

Page 26: ...ass installation for METPOINT OCV For calibration maintenance and service it is recommendable to make use of the BEKO service To facilitate these works a bypass see the example below should be installed This bypass is also advantageous when cleaning the device ...

Page 27: ...POINT OCV device is unpacked and stored approximately three hours prior to installation at the place of installation so as to allow the temperature adaption to the ambient temperature During this period the sensor unit must not be connected to the power supply Careful observance of this point is imperative in particular in the case of major temperature differences between the transport place of st...

Page 28: ...nstallation 28 METPOINT OCV Removal of the sheet package step 4 4 Prior to removing the sheet please make sure to wear oil and grease free gloves and see that the probe is not damaged during the removal ...

Page 29: ... be carried out by correspondingly qualified personnel Never carry out works on a plant which is under pressure The user must ensure that the METPOINT OCV is never operated at a pressure exceeding the value indicated on the type plate Exceeding the maximum operating pressure can cause both injuries and severe damage to the measuring device The sampling probe has a G 3 8 internal thread connection ...

Page 30: ...ep 6 into the thread at the measuring section Make sure not to damage the stationary seal ring when doing so Removal of the probe closure step 9 9 Please remove the closing plug V with the second stationary seal ring with a suitable hollow hexagon wrench Connection of the probe with the sensor unit and mounting of the stationary seal ring step 10 10 Connect the probe 3 with the sensor unit 1 Pleas...

Page 31: ...probe 3 into the desired position 13 Now tighten the union nut 4 by means of an SW 22 open ended spanner with a quarter turn in clockwise direction 14 Using an SW 24 open ended spanner which is applied to the screw connection body 5 you will prevent twisting of the sensor unit 1 Option Stainless steel ball valve with wing Connection 3 8 Oil and grease free You will find installation instructions i...

Page 32: ...ls covering the screwing zone must be levered out carefully 19 Fix the housing of the evaluation unit on the wall in the vicinity of the probe For this purpose use the four through bores Ø 6 mm You will find a hole director in the Appendix to these operating instructions Make sure that a screwdriver with a sufficiently long shaft is available WARNING Unauthorised intervention Unauthorised interven...

Page 33: ... Protection against damage through electrostatic charging The device contains electronic components which may be sensitive to electrostatic discharge ESD The contact with electrostatically charged persons or objects compromises these components In the worst case they are immediately destroyed or will fail subsequent to the start up Observe the requirements stipulated in EN 100015 1 to minimise or ...

Page 34: ...ovisions in force at the place of installation of the METPOINT OCV the connection and installation must be carried out by specialists who are qualified accordingly Make sure that no parts of the measuring devices are energised and that the devices cannot be connected with the electric supply mains during service measures DANGER Missing earth connection When the earth connection protective earth is...

Page 35: ... delivery For this purpose the actual operating conditions are simulated Apart from this it can happen that the measuring device is damaged during the transport Therefore we recommend you examine the specified function of the METPOINT OCV in detail subsequent to delivery and during the first hours of operation The start up must be carried out by qualified and authorised skilled persons It is vital...

Page 36: ...erature adaption to the ambient temperature During this period the sensor unit must not be connected to the power supply 3 Electrical installation Make sure that the connection between the evaluation unit with user interface display and the sensor unit was established with the supplied signalling cable Establish the connection with the power supply sensor unit and evaluation unit Make sure to swit...

Page 37: ...tings to be chosen Subsequent to switching on the power supply of the evaluation unit the operating system requires approx 30 seconds to start the system The following start screen will appear Subsequently the device will switch over to the main menu You can now make all required settings For this purpose please follow the procedure on the next pages Using the password To get access to several sel...

Page 38: ... selection box will appear on the display Enter the password 04321 Confirm with OK in the selection window Confirm with OK below the password Subsequently the selected submenu will open and you may continue with your selection settings Main menu Firstly please choose SETTINGS ...

Page 39: ...djusted values at the start or re start of the device After an interruption of the power supply for example an autostart takes place after 42 seconds In this case the pre adjusted values are retrieved for measurement X Compressor Oils Choose the oil type used in your compressor Should this oil type not have been entered please choose between mineral oil and synthetic oil ...

Page 40: ... on Set A click on OK does not lead to the storage of date and time as the only exception as it is not foreseeable how long the user will stay in the menu after the setting NETWORK Mark the selection box Automatic DHCP for example For further settings please observe our separate instructions ...

Page 41: ...stall a new software version the device must be connected with a PC notebook via the network tap and the Windows software started on a PC notebook Click on Wait for Update at the device Choose the respective device on the PC and start the update Wait until the message appears at the device informing you that the update has been completed ...

Page 42: ...ction Z The measuring gas connection M needs to be closed The PURIFICATOR reference gas generation unit is not used in this mode In the Measurement menu when selecting the gas type a warning will inform you that this mode is activated NOTE Please use this mode only after prior consultation with BEKO Close measuring gas connection M Connect zero air to Z Connect measuring gas to C The max permissib...

Page 43: ...lect list The other select list is disabled When choosing Custom Oil oil with a self calculated factor can be measured When the ScientificMode Settings ScientificMode is activated a corresponding warning is shown NOTE Please use this mode only after consultation with BEKO Close measuring gas connection M Connect zero air to Z Connect measuring gas to C The max permissible operating pressure in the...

Page 44: ...ement NOTE METPOINT OCV operates fully automatically Only after the first measuring cycle has expired at the latest after five minutes will the device indicate measured values Subsequently the values on the display will reload automatically every two minutes ...

Page 45: ...Start up METPOINT OCV 45 At this point important details regarding the device and the device configuration are available which are required during service measures ...

Page 46: ...s follows Click on the display field of the adjusted limit value to modify it in accordance with your requirements Click on the alarm value A selection window with digits CLEAR and OK will appear Enter the password 04321 Confirm with OK in the selection window Confirm with OK below the password ...

Page 47: ...d with digits CLEAR and OK opens Click on CLEAR to delete the previous alarm value Enter the new alarm value Click on OK in the input field The window will close Confirm the adjusted alarm value with OK Measurement will not be interrupted by these setting measures ...

Page 48: ...e checks setting and service measures exclusively carried out by authorised skilled personnel 2 Calibration works can only be implemented by BEKO SERVICE 2 Authorised skilled personnel are persons who are authorised by the manufacturer with experience and technical training who are well grounded in the respective provisions and laws and capable of carrying out the required works and of identifying...

Page 49: ...ion current measured value 2 Indication classification residual oil content in accordance with ISO 8573 1 3 Indication adjusted alarm value 4 Selection box for main menu 5 Indication of the mean measured value of the past 10 measurements 6 Selection box for service level ...

Page 50: ...f the device at regular intervals of the device s memory by means of the software Check these values with regard to temporary exceeding of the limit value 5 The indication of the measured value is updated every two minutes During this time measurement continues in the background 6 Total reset of the device can only be effected through interruption of the power supply Please make sure that temperat...

Page 51: ...horised skilled personnel 3 Calibration works can only be implemented by BEKO SERVICE 13 3 1 Trouble indications Working pressure too low Please increase the operating pressure For minimum value see manual Betriebsdruck zu gering Bitte Betriebsdruck erhöhen Minimaler Wert siehe Betriebsanleitung 3 Authorised skilled personnel are persons who are authorised by the manufacturer with experience and t...

Page 52: ...www beko de 13 3 2 Service indications ATTENTION Calibration required Please contact the BEKO Service ACHTUNG Kalibrierung erforderlich Bitte BEKO Service kontaktieren www beko de For the sake of operating safety the performance of the sensor technology is constantly checked during the measurements In the event that a defined safety limit value has not been reached an alarm will be activated infor...

Page 53: ...nsulted BEKO Close the connection for measuring gas M Connect Zero Air to Z Connect measuring gas to C ACHTUNG Bitte benutzen Sie diesen Modus nur nach Rücksprache mit BEKO Messgas Anschluss M schließen Null Luft an Z anschließen Messgas an C anschließen www beko de 13 4 Measured value memory All measured values are documented in an internal memory 2 GB according to date and time and can be read o...

Page 54: ... 1 2 9 11 onwards DANGER Missing connection with the protective conductor The connection with the protective conductor must be ensured before establishing an electrical connection with the electric circuit of the potential free contact Prior to removing the power plug of the device de energise the potential free contact The removal plugging in of the plug for the potential free contact while energ...

Page 55: ...cle M 16 For the transmission of the alarm a three pole cable box M 16 can be connected at position 1 at the evaluation unit Plug and socket connectors are operating resources that when properly used under voltage must not be plugged in or disconnected ...

Page 56: ...h screen ring Three pole M 16 Cable bushing 4 6 mm Available as accessories Order number 4014142 The alarm contact is designed as a potential free change over contact Maximum load of the contacts 230 VAC 5 A ohmic load 24 VDC 5 A ohmic load ...

Page 57: ...Operation METPOINT OCV 57 Example of a loading of the alarm contact with 24 VDC The potential free alarm contact of the METPOINT OCV functions as follows 1 Mode with inactive autostart See Settings menu ...

Page 58: ...e Start screen without activated autostart Alarm remains active Setting in the Measurement menu Alarm remains active Start measurement Alarm becomes inactive Alarm limit value exceeded Alarm active Warning screen pressure too low no pressure Alarm active Warning screen measurement range exceeded Alarm active Warning screen sensor test Alarm active ...

Page 59: ...ve until the start screen appears Start screen Alarm active Autostart of the measurement while the start screen is displayed Alarm becomes inactive Alarm limit value exceeded Alarm active Warning screen pressure too low no pressure Alarm active Warning screen measurement range exceeded Alarm active Warning screen sensor test Alarm active ...

Page 60: ...apter Non observance of the installation and operating instructions involves risks for persons and systems If you have any queries regarding these instructions please contact BEKO TECHNOLOGIES GMBH This chapter applies to METPOINT OCV from software version 1 3 5 0 onwards The connection for the METPOINT OCV analogue output is at the evaluation unit 1 1 Two pole M 16 flange socket for the connectio...

Page 61: ...Available as accessories Order number 4014143 CAUTION The 4 20 mA interface is designed as an active current source and is galvanically separated from the rest of the circuit by a 1 kV isolation barrier The current to be measured depends on the connected load Only a passive current sink is to be connected to the 4 20 mA interface For correct functioning the connected load must lie within a range b...

Page 62: ...can be configured in accordance with your requirements To scale the 4 20 mA signal please proceed as follows 1 Detect the residual oil content range of your compressed air 2 Connect the 4 20 mA analogue output to your system 3 Choose the scaling suitable for your purposes in the Settings 4 20 mA menu ...

Page 63: ...residual oil content values indicated in the METPOINT OCV MEASUREMENT mode lie in the range of 0 1 mg m please enter 0 001 into the blue field and confirm with OK After confirmation with OK the value for Full Scale and the resolution are indicated In this example the following settings are applicable Scaling 0 1 mA corresponds to 0 001 mg m Scaling initial value 4 0 mA corresponds to 0 000 mg m Sc...

Page 64: ...0 00 mg m Scaling final value Full Scale 20 mA corresponds to 1 60 mg m Example setting 3 If the residual oil content values indicated in the METPOINT OCV MEASUREMENT mode lie in the range between 1 0 mg m and 5 0 mg m please enter 0 1 into the blue field and confirm with OK Scaling 0 1 mA corresponds to 0 1 mg m Scaling initial value 4 0 mA corresponds to 0 0 mg m Scaling final value Full Scale 2...

Page 65: ...ing unit so that they match Notes 1 Until the indication of the first measured value the value which was assigned to the 4 mA is displayed at the start of the measurement 2 During adjustments at the device measurement is interrupted no value is indicated 3 When the device is deactivated no values are indicated either 13 6 Reading out of the measured values via the Ethernet connection See separate ...

Page 66: ...Declaration of conformity 66 METPOINT OCV 14 Declaration of conformity ...

Page 67: ...ective 2004 108 EC EMC Directive electromagnetic compatibility Harmonised standards applied EN 61010 1 Safety requirements for electrical equipment for measurement control and laboratory use EN 61326 1 Electrical equipment for measurement control and laboratory use EMC requirements Year of CE labelling 2009 The products are labelled with the sign shown below This declaration only refers to product...

Page 68: ...e function of the reference gas generation unit once a day For this purpose check whether or not the LED inside the sensor unit flashes see the area that is marked blue It may be required to choose an inclined angle of view When the LED flashes the reference gas generation unit is functional In the event that the LED light remains constant or that the LED is switched off please immediately contact...

Page 69: ...e device for repair purposes By continuously tracking the calibration results the user will be able to ascertain the typical long term behaviour of the employed measuring devices and determine the calibration intervals for his employment conditions on this basis and to extend or reduce these depending on the results Calibration cycle At very high demands on the measuring accuracy we recommend sche...

Page 70: ...ng sections which are manufactured according to the specifications of BEKO TECHNOLOGIES we recommend the following guide values for the minimum flow of the compressed air in the measuring sections to ensure representative sampling Nominal diameter DN Thread size R EN 10 255 Medium weight threaded pipes Minimum flow rate DN 10 3 8 Ø17 2 x 2 3 2 9 m3 h DN 15 1 2 Ø 21 3 x 2 6 3 7 m3 h DN 20 3 4 Ø 26 ...

Page 71: ...h the technical data Do not touch the components without oil and grease free gloves textile gloves are recommended during the installation of the ball valve 3 8 A fingermark can affect the measuring results Prior to installation allow compressed air to flow off to remove condensate and particles This prevents needless contamination of the ball valve and of the sensor unit DANGER Overpressure Befor...

Page 72: ...endix 72 METPOINT OCV Mounting of the sensor unit If required the sensor unit can be mounted via the two available bores in the carrier plate on the wall or on a mounting bracket Measuring gas connection M ...

Page 73: ......

Page 74: ......

Page 75: ......

Page 76: ...Translation of the original manual instructions Original instructions are in German METPOINT OCV_manual_en_2012 04 Subject to technical changes errors excepted ...