Beko BEKOKAT CC-360 User manual

EN – English
Installation and operation manual
BEKOKAT
®
CC-360
Catalytic converter
For removing oil from compressed air

Installation and Operation Manual BEKOKAT®
2 / 88 V01 /11-046
Manufacturer: BEKO TECHNOLOGIES GMBH
Im Taubental 7
D-41468 Neuss
Tel. [phone]
www.beko-technologies.com
Issue date: 07-2018
Version: 01
Document-No.: 11-046
Dear customer
Thank you for purchasing the BEKOKAT® CC-360 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 Incline seat valves (7/8) .............................................................................................. 33
3.5.5 Safety valve (9) ........................................................................................................... 34
3.5.6 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
4.3 Bypass System .................................................................................................. 44

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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 ............................................................................................................. 59
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
6.10 RESET for time relay K1T .................................................................................. 77

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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

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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 is the 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.
Environmentally friendly material.
The packaging material is recyclable. Dispose of it according to the applicable
statutory regulations.

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1.2 Signal words according to ISO 3864 and ANSI Z.535
DANGER Imminent hazard
Consequences of non-compliance: serious or even fatal injury
WARNING Potential danger
Consequences of non-compliance: possibly serious or even fatal injury
CAUTION Imminent hazard
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.