Beko BEKOKAT CC-1200 User manual

EN – English
Installation and operation manual
BEKOKAT
®
CC-1200
Catalytic converter
For removing oil from compressed air
Version 11 bar
11-043

Installation and Operation Manual BEKOKAT®
2 / 88 V01 / 11-043
Manufacturer: BEKO TECHNOLOGIES GMBH
Im Taubental 7
D-41468 Neuss
Tel. [phone]
www.beko-technologies.com
Issue date: 07-2018
Version: 01
Document-No.: 11-043
Dear customer
Thank you for purchasing the BEKOKAT® CC-1200 Catalytic Converter. Please follow our
instructions and read this installation and operation manual carefully before installing and
comissioning the catalytic converter. The proper function of the catalytic converter can only be
guaranteed when the described regulations and instructions are strictly observed.

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Table of contents
General ............................................................................................................................. 6
1.1Pictograms and symbols ...................................................................................... 7
1.2Signal words according to ISO 3864 and ANSI Z.535 ......................................... 8
1.3General safety instructions .................................................................................. 9
1.4Special notes for pressurised equipment according to Pressure Directive
2014/68/EU ........................................................................................................ 15
1.5Special safety instructions ................................................................................. 17
1.6Residual risk ...................................................................................................... 18
1.7Intended use ...................................................................................................... 19
1.8Legal warranty and liability for property defects ................................................. 21
Transport and Storage ................................................................................................. 22
2.1Safety instructions .............................................................................................. 22
2.2Transport ............................................................................................................ 24
2.3Requirements for the site ................................................................................... 25
Product information and system description ............................................................ 26
3.1Type plate .......................................................................................................... 26
3.2Product view ...................................................................................................... 27
3.3Function description of the catalytic converter ................................................... 28
3.4Set-up Description ............................................................................................. 30
3.5Description of the components .......................................................................... 31
3.5.1Heat exchanger plate (1) ............................................................................................. 31
3.5.2Catalytic converter reactor (2) ..................................................................................... 31
3.5.3Temperature Control Unit (3) ...................................................................................... 31
3.5.4Heating system (4) ...................................................................................................... 32
3.5.5Incline seat valves (7/8) .............................................................................................. 33
3.5.6Safety valve (9) ........................................................................................................... 34
3.5.7Safety equipment against temperature overruns (5/6) ................................................ 35
3.6Technical data .................................................................................................... 38
3.7Applied EU Directives and harmonised standards ............................................. 40
Installation ..................................................................................................................... 41
4.1Safety instructions .............................................................................................. 41
4.2Fundamental requirements for the installation ................................................... 43

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4.3Bypass System .................................................................................................. 44
4.4Installation examples ......................................................................................... 45
4.4.1Compressed air treatment with a BEKOKAT® catalytic converter ............................... 45
4.4.2BEKOKAT® with Bypass ............................................................................................. 46
4.4.3BEKOKAT® with DRYPOINT® refrigeration dryer and METPOINT® OCV................... 47
4.4.4BEKOKAT® with DRYPOINT® adsorption dryer and METPOINT® OCV ..................... 47
4.5Installation of compressed air connection .......................................................... 48
4.6Electrical installation .......................................................................................... 49
4.6.1Safety instructions ....................................................................................................... 49
4.6.2Electrical connections ................................................................................................. 52
4.6.3Terminals for electrical connections ............................................................................ 53
4.6.4EMERGENCY STOP switch / EMERGENCY STOP device ....................................... 54
Commissioning ............................................................................................................. 55
5.1Safety instructions .............................................................................................. 55
5.2Inspection before commissioning ....................................................................... 57
5.3Operation ........................................................................................................... 58
5.3.1Electric control ............................................................................................................. 5 9 
5.3.2Settings ....................................................................................................................... 60
5.4Initial commissioning .......................................................................................... 61
5.5Notes on the reactor temperature during commissioning .................................. 63
5.6Notes on the operation of the BEKOKAT® ......................................................... 65
5.7Notes on reactor temperature during operation ................................................. 66
5.8Re-commissioning after shut down .................................................................... 67
Troubleshooting and remedying malfunctions .......................................................... 68
6.1Safety instructions .............................................................................................. 68
6.2Reactor temperature> + 200 °C ......................................................................... 69
6.3Reactor temperature> + 60 °C ........................................................................... 70
6.4Safety temperature monitor (TW) activated ....................................................... 71
6.5Safety temperature monitor (STW) activated ..................................................... 72
6.6Short-term power failure .................................................................................... 73
6.7Error display ....................................................................................................... 74
6.8Defective contactor or defective relay module ................................................... 75
6.9Defective fuse .................................................................................................... 76

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6.10RESET for time relay K1T .................................................................................. 77
Maintenance .................................................................................................................. 7 8 
7.1Safety instructions .............................................................................................. 78
7.2Decommissioning for service, maintenance or repair ........................................ 80
7.3Maintenance schedule ....................................................................................... 81
7.4Recurring inspections ........................................................................................ 82
7.5Exchange of catalyst agent ................................................................................ 83
7.6Waste code ........................................................................................................ 83
Disposal ......................................................................................................................... 84
8.1Decommissioning ............................................................................................... 84
8.2Disposal ............................................................................................................. 84
Appendix ........................................................................................................................ 85
Service addresses ........................................................................................................ 88

Installation and Operation Manual BEKOKAT®
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General
The BEKOKAT® described in this installation and operating manual is used to remove oil from
the compressed air and is designed and manufactured according to the latest state-of-the-art
technology.
All components are subjected to a continuous quality control throughout the manufacturing
process according to the criteria of our quality management system.
BEKO TECHNOLOGIES GmbH is certified according to ISO 9001:2008.
This installation and operation manual of the BEKOKAT® must be carefully read and fully
understood by the responsible specialist personnel before the start of all work (installation,
commissioning and maintenance).
A prerequisite for safe handling and trouble-free operation of this plant device is compliance
with all stated safety instructions and handling instructions.
The operating instructions are an integral part of the system and must be available at all times
at the location of use of the BEKOKAT® .
The local accident prevention regulations applicable for the product and the general safety
regulations must be complied with.
This documentation, including all its parts, is protected by copyright. Any use or modification
outside the strict limits of the copyright law is prohibited and punishable without the consent of
BEKO TECHNOLOGIES GmbH. This applies, in particular, to duplication, reproduction,
translation, microfilming and storage and processing in electronic systems.


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1.1 Pictograms and symbols
The safety instructions in this operating instructions are intended to prevent hazards. They are
located in the operating manual before an action / work / activity is described which can create
a hazard.
General hazard symbols (danger, warning, caution).
Warning about electric voltage.
Warning about hot surfaces.
General instructions.
The installation and operation manual guidelines must be strictly adhered to.
Wear eye protection
Wear safety shoes.
Wear protective clothing.
Information for fire fighting.

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Environmentally friendly material.
The packaging material is recyclable. Dispose of it according to the applicable
statutory regulations.
1.2 Signal words according to ISO 3864 and ANSI Z.535
DANGER Imminent danger
Consequences of non-compliance: serious or even fatal injury
WARNING Potential danger
Consequences of non-compliance: possibly serious or even fatal injury
CAUTION Imminent danger
Consequences of non-compliance: injury and/or damage to property
NOTE
Additional notes, information, tips
Consequences of non-compliance: Disadvantages during operation and
maintenance.


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1.3 General safety instructions
NOTE Installation and operation manual
 Before reading this manual, make sure that it refers to your plant
model. This document contains important information and
instructions for the safe operation of the plant. Non-compliance with
these installation and operating instructions can cause hazards for
people and the plant.
 Before executing any work, all specialist technical personnel1 must
therefore have read the installation and operating instructions.
 A copy of these operating instructions must be kept near the
installation location where it is accessible all times.
 In addition to the instructions in this installation and operating
manual, always comply with the relevant national and statutory
regulations for machine operation, accident prevention and safety
for the respective application. This also applies to the use of
accessories and spare parts.
DANGER Insufficient qualification
 Improper use and handling of the BEKOKAT® can lead to
considerable damage to persons or property. All activities described
in these operating instructions such as operation, function tests,
installation, adjustment and maintenance work may only be carried
out by qualified specialist personnel.
 This installation and operation manual of the BEKOKAT® must be
carefully read and fully understood by the responsible specialist
personnel before the start of all (installation, commissioning and
maintenance) work.
1) Specialist technical personnel
Specialist technical personnel are people who, due to their professional qualification and
knowledge in the field of measuring, control and pneumatic technology, and their knowledge
of the applicable statutory regulations, guidelines and standards are in a position to
independently foresee potential dangers in relation to the use of the device and who are
qualified to perform the tasks described in this manual. Special operating conditions (e.g.
aggressive media) require additional knowledge.

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DANGER Compressed air! Gases under high pressure
Any contact with escaping compressed gas or not secured
system parts will create danger of serious injuries or death.
 Only executeinstallation work and maintenance work in a
depressurised status.
 Use only pressure-resistant installation materials and suitable tools
that are in proper working order.
 Only ever use fittings and connecting elements which are approved
for this application. Always adhere to the manufacturer's information
and instructions.
 Always inspect all plant parts before pressurising the system and
tighten them.
 Open valves slowly to prevent pressure blow outs during operation.
 The compressed air lines must be permanently installed.
 Always prevent people or objects from being affected by escaping
compressed gas.
 Prevent vibrations, oscillations and impact from being transferred to
the plant.
 Perform a leakage test.
 Never carry out structural modifications on the plant!
 Use only original spare parts and accessories!
 The general statutory safety and accident prevention regulations
apply.

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DANGER Electric power
Touchable conductive parts can lead to dangerous voltages / mains
voltage during installation and maintenance or in case of defects. Hazard
resulting in of serious or even fatal injury from electric shock when coming
into contact with uninsulated parts or mains voltage.
 All work on the electrical components of the BEKOKAT® may only be
carried out by suitably trained specialists.
 The BEKOKAT® must not be put into operation if the power supply
cables have been damaged or parts of the housing have been
damaged or removed.
 The valid legal regulations and provisions at the local place of use
must be complied with without exception.
 Observe the electrical data provided on the rating plate.
 Work on the electrical connections may only be executed when the
power supply is switched off. The system must be secured against
unintentional restart.
 Only utilise components for the electrical installation which have a
current authorisation and are labelled with a CE-Identification
marking.
 The wire ends to be connected to the control unit must be equipped
with wire-end ferrules.
 All electrical connections must be inspected before commissioning
and at regular intervals.
 The removal of seals and labels on safety equipment is prohibited.
NOTE MAINTENANCE
 The BEKOKAT® may only be used by qualified and authorised
specialist personnel in accordance to the technical data.
 The removal of seals and labels on safety equipment is strictly
prohibited.

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WARNING Operation of plant outside limit range
If the specified limits are undershot and/or exceeded, then function and
operating malfunctions could occur and cause danger for people and
material.
 BEKOKAT® may only be used in accordance with its intended use
and within the permitted limiting values stated on the rating plate as
well as in the technical data.
 The maximum compressed air volume flow at the inlet of the
BEKOKAT® system must not exceed 1200 m³ / h (see data type plate
and technical data).
 Always adhere to the permitted storage and transport conditions.
WARNING Hot surface
 Risk of injury to people property damage - risk of fire!
 Before carrying out any work on BEKOKAT®, allow the system to cool
down!
 Secure and mark the accessible places.
DANGER Fire safety
A fire at the plant might result in serious injury or damage to materials.
 If there are potential ignition sources at the place of installation in the
plant, the operator must take suitable safety measures to ensure that
the permissible operating parameters of the plant are not exceeded.

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WARNING Fire
 Adjust the fire extinguishing measures to the working environment.
 Never use water in a full jet for safety reasons.
 Wear a respiratory mask independent of ambient air.
DANGER Excessive pressure / temperature
 Suitable measures must be implemented to ensure that the
permissible operating pressure and operating temperature are not
exceeded on the plant.
 It is the duty of the operator to ensure that the connected pressure
generator is protected against exceeding the maximum operating
overpressure of 11 bar (g) and the temperature limits on the
BEKOKAT®.
 It must be ensured that the pressure generating compressor and the
compressed gas system are secured and safe.
 Suitable measures must be implemented to ensure that the
permissible operating temperature is not inadvertently exceeded by
ambient conditions at the installation location.
CAUTION Use of protective clothing
To avoid injuries to the feet and hands during transport of the BEKOKAT®
, the skilled technical personnel must wear sufficient protective clothing
and safety shoes!
WARNING Equipment to prevent dangerous conditions
 The BEKOKAT® must not be used as the sole means of averting
dangerous conditions on machinery and equipment.
 All machines and plants must be designed in such a way that
malfunctions or faulty conditions do not pose a danger to operation
personnel.

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NOTE Risk of malfunction and/or impaired safety
 Insufficient maintenance can result in malfunctions and impaired
safety.
 Perform the maintenance work regularly!
 In any case observe the safety instructions for maintenance,
inspection and assembly work!
 If you have any queries regarding the content of this installation and
operating manual, please contact BEKO TECHNOLOGIES GMBH.
 The system must only be operated and serviced according to the
information in the operating instructions to ensure safe operation.
 In addition to these instructions, always comply with the required
statutory regulations for the application cases for system operation
and company safety regulations as well as accident prevention
regulations.
 This also applies to the use of accessories and spare parts.
 Non-compliance with these installation and operating instructions can
cause hazards for people and the plant.

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1.4 Special notes for pressurised equipment according to
Pressure Directive 2014/68/EU
Proper utilisation of the BEKOKAT® is a fundamental prerequisite for safe operation. The
owner and/or operator must therefore always proceed as follows:
 The BEKOKAT® must only be operated within the pressure and temperature limits
specified by the manufacturer on the rating plate.
 The BEKOKAT® may only be used for fluid group 2 medium according to PED 2014/68
/ EU, i.e. with a medium free of aggressive, corrosive, toxic, flammable and oxidizing
components.
 The housing and frame of the systems must not be welded.
 The BEKOKAT® must neither be operated in insufficiently ventilated rooms nor near
heat sources or flammable, hazardous materials or substances.
 To prevent breakages caused by material fatigue, the BEKOKAT® must be protected
against vibration during operation.
 The maximum permissible operating pressure specified on the manufacturer type plate
must not be exceeded under any circumstances. It is the responsibility of the operating
company to install suitable safety and control devices to prevent excessive pressure.
 The documentation shipped with the BEKOKAT® (manual, operating instructions,
Declaration of Conformity, etc.) must be kept in good condition for future viewing and
reference.
 No objects may be attached or placed on the BEKOKAT® and connecting cables.
 Never carry out welding work on the pressure vessel or alter it in any way!
 Only install the plant in frost-free rooms.
 The operation of the system is permitted only with completely closed and intact
housings and panels. The operation of the system with a damaged housing/casing is
prohibited.
 The compressed air system in which the BEKOKAT® is integrated must have pressure
limiting devices.
WARNING Unauthorised interference

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 Unauthorised interference with the device can cause injury or
damage to the pressure equipment.
 Do not make any unauthorised modifications to the device and use
the pressure equipment only for the intended purpose.
 The removal of seals and labels on safety equipment is prohibited.
WARNING National regulations
 Owners and/or operators of the systems must observe the local and
national pressure equipment regulations in the country of
installation.

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1.5 Special safety instructions
DANGER Compressed air parameters
 Exceeding the maximum pressure can cause damage to the plant.
 Observe the maximum permissible pressure specified on the rating
plate!
NOTE Endangered functional safety
Faulty installation can endanger the functional safety and have a
negative effect on maintenance work.
 The clear width of the pipe connection must be at least as large as
the connection dimension of the BEKOKAT®.
 It is strongly recommended that a shut-off valve be installed before
and after the BEKOKAT® for maintenance work.
 Furthermore, it is strongly recommended to provide the BEKOKAT®
with a lockable bypass line.
 Overloading of the BEKOKAT® can endanger functional safety!
Always observe the permissible temperature and pressure range!
 Do not exceed the permissible volume flow rate and the permissible
operating pressure!
 Do not undershoot the working pressure!
NOTE Maintenance works
 All maintenance work on the BEKOKAT® may only be carried out
with the catalytic converter switched off, depressurised and voltage-
free.
 The removal of seals and labels on safety equipment is prohibited.

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1.6 Residual risk
The BEKOKAT® catalytic converter corresponds to the current specifications of safety
technology. Nevertheless, certain residual risks remain:
 Hazards caused by incorrect transport and storage.
 Hazards caused by electrical voltage when using improper electrical connection cables or
touching live parts with the control box open.
 Hazards caused by improper commissioning and/or assembly personnel who are not
trained.
 Hazards caused by incorrect or irregular maintenance.
 Hazards caused by ignoring the safety instructions.
 Hazards caused by circumventing or disarming the safety equipment or devices.
 Hazards caused by operating outside permissible pressure and temperature limits.
 Hazards caused by operating with a medium other than the approved one.
 The safety labels and/or safety instructions in this operating manual indicate additional
residual risks. Always adhere to all safety instructions.
DANGER Incorrect installation location
Never install the BEKOKAT® in explosion hazardous areas.

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1.7 Intended use
The BEKOKAT® is used to remove oil from the compressed air. The compressed air must be
free of aggressive, corrosive, caustic, toxic, flammable or oxidising substances.
Any other utilisation is thereby considered to be non-intended use.
The manufacturer shall not be liable for damage caused by improper use. All responsibility for
any other possible resulting damage will be solely borne by the owner and/or operator.
The proper and safe operation of the BEKOKAT® includes compliance with the installation
instructions in this manual, in particular the instructions regarding:
 Location of installation/operation, installation conditions
 Voltage supply and frequency
 Pressure and temperature of the inlet air
 Ambient temperature
 Media of fluid group 2 according to DGRL 2014/68/EU free of aggressive, corrosive,
caustic, toxic, flammable and oxidising components
 Surrounding area free of aggressive, corrosive, caustic, toxic, flammable or combustion
supporting materials and substances.
 Connecting the alarm contacts and their signal processing.
The system is delivered as approved at the factory. The operator only has to carry out the
connections to the supply networks as described in the following chapters.
WARNING Equipment to prevent dangerous conditions
 The BEKOKAT® must not be used as the sole means of averting
dangerous conditions on machinery and equipment.
 All machines and plants must be designed in such a way that
malfunctions or faulty conditions do not pose a danger to operation
personnel.

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WARNING Danger caused by incorrect use
The BEKOKAT® complies with the latest technology and is safe to
operate. There are however some residual risks which may result from
the system if improperly used and operated by untrained personnel.
Improper use includes:
 Exceedance of permissible maximum operating pressure
 Exceedance of maximum permissible operating temperature
 Exceedance of maximum permissible volume flow
 Use with a medium that does not comply with fluid group 2 according
to PED 2014/68/EU
 Bypassing of or interference with safety equipment
 Ignoring of alarms
 Use of the system for a purpose other than the intended