Beko CLEARPOINT 3eco S040 User manual

en
CLEARPOINT® 3eco coalescing filter
08-308
Installation and operation manual
> S040
> S050
> S055
> S075
> M010
> M012
> M015
> M018
> M020
> M022
> M023
> M025
> M027
> M030
> M032

Content
1. General.............................................................................................................................................4
1.1 Contact............................................................................................................................................................4
1.2 Information regarding installation and operation manual .................................................................4
1.3 Other applicable documents......................................................................................................................4
1.4 Explanation of the symbols and pictograms utilised............................................................................5
1.4.1 In the documentation ......................................................................................................................5
1.4.2 On the device.....................................................................................................................................6
1.5 Intended use...................................................................................................................................................7
1.6 Resonably foreseeable inappropriate use...............................................................................................8
1.7 Legal warranty and liability for property defects..................................................................................8
1.8 Target group and personnel .......................................................................................................................9
1.9 Responsibility of the owner........................................................................................................................9
2. Safety-related information........................................................................................................... 10
2.1 General instructions...................................................................................................................................10
2.2 Safety instructions......................................................................................................................................11
3. Transport and storage................................................................................................................... 12
4. Product information ..................................................................................................................... 13
4.1 Product description....................................................................................................................................13
4.2 Product overview ........................................................................................................................................13
4.3 Product identication ................................................................................................................................14
4.4 Function description ..................................................................................................................................16
4.4.1 Filtration............................................................................................................................................16
4.4.2 Condensate discharge through oat drain ...............................................................................17
4.4.3 Condensate discharge through BEKOMAT...............................................................................18
4.5 Scope of delivery ........................................................................................................................................18
4.6 Type plate......................................................................................................................................................19
4.7 Filter element sticker .................................................................................................................................20
4.8 Maintenance sticker for lter element replacement..........................................................................20
5. Technical data ............................................................................................................................... 21
5.1 Filter performance data.............................................................................................................................21
5.2 Filter element performance data ............................................................................................................22
5.3 Materials .......................................................................................................................................................23
6. Dimensions.................................................................................................................................... 24
7. Assembly ....................................................................................................................................... 26
7.1 Warning.........................................................................................................................................................26
7.2 Assembly work.............................................................................................................................................27
8. Commissioning.............................................................................................................................. 29
8.1 Commissioning tasks .................................................................................................................................29
9. Maintenance and servicing........................................................................................................... 30
9.1 Maintenance schedule...............................................................................................................................30
9.2 Cleaning ........................................................................................................................................................30
9.2.1 Warning.............................................................................................................................................30
9.2.2 Cleaning work ..................................................................................................................................31
9.3 Visual inspection.........................................................................................................................................31
9.4 Replace the oat drain...............................................................................................................................32
9.5 Replace the lter element.........................................................................................................................36
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9.6 Leakage test .................................................................................................................................................39
10. Shut down ................................................................................................................................... 40
11. Disassembly ................................................................................................................................ 41
11.1 Warning.......................................................................................................................................................41
11.2 Disassembly work.....................................................................................................................................42
12. Disposal....................................................................................................................................... 44
12.1 Warning.......................................................................................................................................................44
12.2 Disposal work ............................................................................................................................................44
13. Spare parts and accessories........................................................................................................ 45
13.1 Spare parts .................................................................................................................................................45
13.2 Accessories attachment components top ..........................................................................................45
13.3 Accessories attachment components bottom...................................................................................46
14. Troubleshooting / FAQ............................................................................................................... 47
15. Product approvals and registration marks ................................................................................ 48
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1. General
1.1 Contact
Manufacturer Customer service and tools
BEKO TECHNOLOGIES GmbH
Im Taubental 7 | D-41468 Neuss
Tel. + 49 2131 988 - 1000
[email protected]om
www.beko-technologies.com
BEKO TECHNOLOGIES GmbH
Im Taubental 7 | D-41468 Neuss
Tel. + 49 2131 988 - 1000
[email protected]
www.beko-technologies.com
1.2 Information regarding installation and operation manual
INFORMATION Copyright protection
iThe contents of the installation and operation manual in the form of text, gures, illustrations,
photographs, technical drawings, diagrams and other representations are protected by the
copyright of the manufacturer. This applies especially to duplication, reproduction, microlming
and storage as well as processing in electronic systems.
Publication date Revision status Reason for amendment Scope of amendment
31/10/2018 00_01 Changes to standards and
regulations Completely new version
The installation and operation manual, hereinafter referred to as the manual, must always be stored close to the product
and be in a permanently legible condition.
The manual must be handed over along with the product if it is sold or passed on.
NOTE Follow the instructions given in the manual!
This manual contains all the basic information required for safe operation of the product and
must therefore be read before any actions are performed. Otherwise personal and material
hazards as well as functional and operational malfunctions can occur.
1.3 Other applicable documents
This manual contains all the necessary steps for installation and operation of the CLEARPOINT® 3eco coalescing lter.
More detailed information about the installation and operation of the accessories is contained in the following
installation and operation manual:
• BEKOMAT® 20
• BEKOMAT® 20 FM
• CLEARPOINT® Dierential pressure gauge
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1.4 Explanation of the symbols and pictograms utilised
The symbols and pictograms utilised below indicate safety-relevant and important information which must be adhered
to when handling the operating material and to ensure safe and optimum operation.
1.4.1 In the documentation
Symbol/Pictogram Description/Explanation
General hazard symbol (danger, warning, caution)
Pressurised system
Observe installation and operating manual
General instructions
Wear respiratory protection FFP 3
Wear safety footwear
Wear protective gloves (uid-resistant)
Wear hearing protection
Wear safety goggles with side shields
General information
i
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1.4.2 On the device
Symbol/Pictogram Description/Explanation
General hazard symbol (danger, warning, caution)
(This symbol can be found on the type plate and on the maintenance sticker for lter
element replacement.)
Maintenance sticker for lter element replacement
When the next scheduled lter element replacement is due is marked on this sticker, and
that the installation and operation manual should be followed.
4038104
W5822635/002
CLEARPOINT
Flow
04FX (04F,04G)
Made in Germany
Filter element sticker
This sticker is located on the base of the lter element and provides information about the
lter element and the direction of ow.
eco label:
Products with this sticker have special added value in the form of energy saving and are
allocated to the eco line of BEKO TECHNOLOGIES GMBH products.
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1.5 Intended use
CLEARPOINT® filters and accessories
The CLEARPOINT®3eco coalescing lter, also referred to as lter below, is used for the ltration of aerosols and solid
particles in compressed gas systems.
Any use of this system other than the use described in this manual is hereby deemed to be non-intended and can cause a
hazard for the safety of people and the environment.
• Only use lters and accessories within the operating parameters given in the technical data and the agreed delivery
conditions.
• Only use lters and accessories within a pipeline system designed for the technical data with appropriate
connections, pipe diameters and assembly clearance.
• Only use the lters and accessories for the treatment of compressed gases of uid group 2 according to Pressure
Equipment Directive 2014/68/EU which are free of aggressive and corrosive components.
• Only use lters and accessories in non-explosive hazardous areas.
• Only use lters and accessories away from direct solar radiation and heat sources as well as areas subject to frost.
• Only combine the lters and accessories with the products named and recommended by
BEKO TECHNOLOGIES GMBH in the manual.
Before using the lters, the operating company must make sure that all conditions and prerequisites for intended use are
given.
The lter is exclusively designed for stationary use in a commercial or industrial area. All the assembly, installation,
operation, disassembly and disposal work described may only be performed by qualied skilled personnel.
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1.6 Resonably foreseeable inappropriate use
Reasonably foreseeable inappropriate use is deemed to have occurred if the lter or any accessories are used in any
other way than that described in the chapter "Intended use". Reasonably foreseeable inappropriate use includes the use
of the product in a manner not intended by the manufacturer or supplier but which may result from foreseeable human
behaviour.
Reasonably foreseeable inappropriate use includes:
• Executing of modications of all kinds, in particular design and process engineering interventions, as these can lead
to personal injury and material damage as well as functional and operational malfunctions and device failure.
• The overriding, bridging or non-application of existing or recommended safety devices.
• The use for treatment of compressed gases which are are not included in uid group 2 in accordance with PED
2014/68/EU or contain aggressive components. In cases of doubt a gas/condensate analysis must be carried out.
This list is not exhaustive as not all possible inappropriate use can be foreseen in advance. If the operating company is
aware of any inappropriate use of the lter or accessories which are not listed here, the manufacturer must be informed
immediately.
1.7 Legal warranty and liability for property defects
The owner and operator must take into account the intended use. The owner and operator will be completely liable for
every not described action and utilisation which exceeds the stated intended use.
All liability or warranty claims will be invalidated insofar as the lter is not operated according to the intended use or is
operated outside the limits specied in the technical data.
This includes:
• incorrect technical installation, commissioning, servicing, maintenance or operation
• the use of defective components
• non-compliance with the safety-relevant information, action steps and instruction contained in this manual
• the performance of any kind of modication, in particular constructive and process technology interventions on the
product
• the use of third-party spare parts or accessories, which have not been approved by the manufacturer, during
maintenance and repair work
• Non-compliance with servicing, maintenance and inspection intervals
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1.8 Target group and personnel
This manual addresses the specialist personnel listed below who are involved with work on the lter or the accessories.
INFORMATION Personnel requirements
i
The personnel may not execute any actions on the lter or the accessories when they are
under the inuence of drugs, medications, alcohol or other substances that may impair their
consciousness.
Skilled personnel- Transport and storage
Skilled personnel - Transport and storage are people who, due to their training, professional experience and
qualications, have all the necessary skills to safely execute all actions in connection with the transport and storage of
the operating material, to instruct, to recognise possible dangerous situations independently and to execute measures
to avoid danger.
Skills include experience with hoists, forklifts and lifting equipment and knowledge of local laws, standards and
guidelines relating to transport and storage.
Qualied personnel - compressed gas technology
Skilled personnel - compressed gas technology are people who, due to their training, professional experience and
qualication, possess all the necessary capabilities to safely execute actions, and instruct all actions related to
compressed gases and pressurised systems, to independently foresee potential hazardous situations and implement
appropriate measures to avert any danger.
The capabilities include, in particular, experience in handling measurement and control technology as well as
knowledge of the regionally applicable laws, standards and regulations for compressed gas technology.
1.9 Responsibility of the owner
The responsible owner must ensure the following to prevent accidents, incidents and adverse eects on the
environment:
• Before all actions, check to ensure that the manual available does in fact belong to the product.
• Always use, maintain and service the product properly.
• All applicable statutory requirements, safety regulations and accident prevention regulations have been adhered to.
• All regulations and operation manual for safe working and information regarding behaviour in the event of accidents
and res at the operating location are accessible to personnel at all times.
• The product is used with recommended and functioning safety devices that are not overridden.
• Always have assembly, installation and maintenance work carried out by qualied skilled personnel only.
• Personnel have the recommended personal protective equipment at their disposal and it is used.
• Appropriate technical safety measures have been implemented to ensure that the permissible operating parameters
are not exceeded or undershot.
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2. Safety-related information
2.1 General instructions
Safety instructions warn against residual risks when handling the product. Warning notices in the instructional text
precede the procedure that poses a hazard to personnel or the environment.
These safety and warning notices must be strictly observed in order to prevent accidents, personal injury, damage to
property and impairments during operation.
Structure of the safety instructions
The content of the safety instructions is based on the SAFE principle:
S - Safety symbol and signal word
A - Type and source of danger
F - Possible consequences of disregarding the danger in the order of its severity
E - Measures to prevent danger
Structural design of the safety instructions:
SIGNAL WORD Type and source of danger!
Safety symbol
Possible consequences if the danger is ignored
• Measure to prevent the danger
Signal words according to ISO 3864 and ANSI Z.535.6
DANGER Imminent danger
Consequences of non-compliance: Death or serious personal injury
WARNING Imminent danger
Consequences of non-compliance: Death or serious personal injury are possible
CAUTION Potential danger
Consequences of non-compliance: injury and/or damage to property
NOTE Additional notes, information, tips
Consequences of non-compliance: Disadvantages during operation, actions and maintenance.
No danger to people or regarding the safe operation.
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2.2 Safety instructions
In order to prevent accidents, personal injury and damage to the device as well as impairments during operation, it is
essential to adhere to the specied safety and warning notices.
The personal protective equipment specied in the safety instructions must be selected and made available by the
operating company depending on the system parameters and properties.
DANGER Operation of plant outside the permissible limit range!
Operation of the product outside the permissible limits and operating parameters, unauthorised
intervention and modications may result in death or serious injury.
• For safe operation of the product, always adhere to the limit values, operating parameters
and maintenance intervals as well as the set-up and ambient conditions specied on the type
plate and in the manual.
• Inspect whether the operating parameters have been amended or restricted by the use of
accessories.
• Only use the product for its intended use.
DANGER Pressurised system!
Death or serious personal injury can result through contact with fast or suddenly escaping
compressed air or through bursting system parts
• All work on the system must be carried out in the depressurised state and with the system
secured against unintentional pressure build-up.
• Set up a safety zone around the system during all assembly, installation, maintenance and
repair work.
• Before applying pressure to the system, check all pipe connections and tighten if necessary.
• Slowly pressurise the system with compressed gas.
• Avoid pressure blows and high dierential pressures.
• Assemble all pipes without mechanical stress. Avoid any vibrations occurring in the pipe
network by using vibration dampers.
• Always keep exactly to the installation and operating instructions given in this manual.
• Always keep inspection and maintenance interval exactly.
• Install xed pipes as supply and discharge pipes.
• Do not carry out any structural changes to the product.
DANGER Use of incorrect spare parts, accessories or installation materials!
The use of incorrect spare parts, accessories or installation materials, as well as auxiliary and
operating materials, may result in death or serious injury. In addition, functional and operational
malfunctions or material damage can occur.
• For all installation, servicing and maintenance work, only use undamaged original parts,
auxiliary and operating materials which are specied by the manufacturer.
• Only use ttings and connecting elements approved for the respective application as well as
suitable tools in perfect operating condition.
• Only use cleaned pipes that are free of dirt and corrosion.
WARNING Non-application of personal protective equipment!
Non-application of personal protective equipment or the use of sub-standard protective
equipment can lead to accidents or personal injuries during work on the product.
• The personal protective equipment recommended, which must be in a awless condition,
must be worn during all work on the product.
• Inspect the personal protective equipment regularly for awlessness and functionality and
replace damaged parts immediately.
WARNING Insucient qualication!
Insucient qualication of the personnel can lead to accidents, personal injury and damage to
the device as well as impairments during work on the operating material.
All work on the product may only be carried out by appropriately qualied skilled personnel.
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3. Transport and storage
WARNING Insucient qualication!
Insucient qualication of the personnel can lead to accidents, personal injury and damage to
the device as well as impairments during work on the operating material.
The work on the operating material described below must only be executed by specialist
personnel during transport and storage.
CAUTION Inappropriate transport or storage!
Inappropriate transport or storage may result in personal injury or damage to the device.
• Wear protective gloves when working with packaging material
• Use personal protective equipment, inspect it regularly for faultlessness and functionality
and replace damaged parts immediately.
• The operating material may only be transported or stored by qualied personnel.
• Handle packaging and operating material with care.
• Pack all parts impact-proof using suitable material.
• Transport and handle the packaging according to the markings (observe lifting gear
attachment points, the centre of gravity and orientation e.g. keep vertical, do not throw etc.).
• Use proper means of transport and lifting equipment that is in proper working order.
• Always adhere to the specied transport and storage parameters.
• Store the operating material only outside of areas exposed to direct sunlight and heat
sources.
Permissible storage and transport conditions, refer to “4.8 Maintenance sticker for lter element replacement” on
Page 20.
NOTE Handling packaging material!
Inappropriate disposal of packaging materials can cause environmental damage.
• The packaging material is recyclable.
• Dispose of the packaging material in accordance with the regional laws, provisions,
guidelines and regulations of the country and place of use.
NOTE Note for transport and storage!
The operating material must be
• stored in the original packaging and retained in a dry as well as frost-free room. The
ambient conditions, transport and storage parameters must never fall short of/exceed
the specications in the technical data chapter.
• Always protect it against external weathering eects even in a packaged condition.
• Secure the plant so that it cannot topple over or fall and protect it against vibration at
the storage location.
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4. Product information
4.1 Product description
CLEARPOINT®3eco coalescing lters are used for the ltration of aerosols and solid particles in compressed gas
systems.
Depending on the requirements, lter elements with dierent ltration stages can be used to achieve the required
compressed air class in accordance with ISO 8573-1.
The condensate accumulated during ltration can be discharged manually or automatically.
4.2 Product overview
The lter is made up of the following components:
4
5
8
9
Fine filter
Type:
Material-no.:
Lot:
Year:
Element:
Elementmat.-no.:
Min./max.working
temperatureTS:
Max.working
pressurePS:
Volume:
Testpressure PT:
Connection:
S040FWF
4002618
201420
2014
04F
4002707
+2... 60 °C / +35 ... +140 °F
1,5.. 16 bar / 22 ... 232 psi
asd
23bar / 334 psi
pipeG 3/8
drainG 1/2
Fluidgroup2
PED97/23/EC / Cat. -
Beko TECHNOLOGIES
http://www.beko-technologies.com
2
6
7
3
1
1a
!
20
Position no. Explanation/description
[1] Inlet at the lter head, additionally marked 1a
[2] Outlet at the lter head
[3] Filter head
[4] Filter element
[5] Safety slide with locking screw
[6] eco label: Products with this sticker have special added value in the form of energy saving and
are allocated to the eco line of BEKO TECHNOLOGIES GMBH products.
[7] Type plate
[8] Filter housing with internal sealing ring
[9] Maintenance sticker for lter element replacement
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4.3 Product identication
The product designation is shown on the type plate and made up of numbers and letter codes. Each code stands for a
lter component and is divided into the following categories:
[1] = Size: Housing
[2] = Filter elements
[3] = Attachment components top
[4] = Attachment components bottom
The product designation is explained below using the example “S040CWF”:
S040CWF
2
2
3
3
4
4
1
1
Attachment
components
bottom
Attachment
components
top
Filter elements
Size: Housing
CX FX
S040
S050
S055
S075
M010
M012
M015
M018
M020
M022
M023
M025
M027
M030
M032
SX
P D W
B T M F C
Z
C F S
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Attachment components top
Position no. Letter code Designation
[3]
PDierential pressure gauge with potential-free contact
DDierential pressure gauge without potential-free contact
W Without indicator unit
Filter elements
Position no. Letter code Designation 99.9% separation
rate solid particles
[μm]
Residual oil
content
[mg/m³]
Compressed air
class in acc. with
(ISO 8573 - 1)
[2]
CX Coarse lter 2 ... 5 ≤ 5 [4: - :4]
FX Fine lter 0.5 ... 1 ≤ 0.05 [2: - :2]
SX Super ne lter 0.1 ... 0.3 ≤ 0.005 [1: - :2]*1
*1Depending on the ambient conditions and operating parameters, class [1: - :1] can also be reached.
Position no. Model series Construction size Designation
[1]
S 040
Filter housing
S 050
S 055
S 075
M 010
M 012
M 015
M 018
M 020
M 022
M 023
M 025
M 027
M 030
M 032
Attachment components bottom
Position no. Letter code Designation
[4]
B BEKOMAT®20
T BEKOMAT®20 FM
M Manual condensate drain
F Float drain, open when pressureless (NO - normally open)
Z Float drain, closed when pressureless (NO - normally closed)
C Without condensate drain
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4.4 Function description
4.4.1 Filtration
With the CLEARPOINT® 3eco coalescing lter, the medium ows through the lter element from the inside to the
outside. Compressed gas ows into the lter element from where it ows through the lter element into the lter vessel.
During this process, particles as well as oil and water aerosols are separated by the lter material. The liquid components
in the lter material move downwards due to gravity, drip o and collect at the base of the lter vessel. From there, they
are drained o automatically or manually. Over time, particles become deposited in the lter material. This results in an
increase in ow resistance (dierential pressure) of the lter element.
The particle charge or degree of pollution of the lter element can be read o using a dierential pressure gauge. More
detailed information about this can be found in the installation and operation manual enclosed with the dierential
pressure gauge.
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4.4.2 Condensate discharge through oat drain
Float drains are mechanical condensate drains that work automatically as they are closed and opened based on the
buoyancy of a oat body [1]. When the condensate [2] in the vessel rises to a certain level, buoyant force pushes the
oat body [1] up and opens the outlet channel [3] for the condensate. The oat body closes again when the condensate
[1] drops to below a certain level. A small amount of condensate remains in the vessel.
Two dierent oat drains are used for discharging the condensate:
• Open when pressureless ([NO] normally open) - at operating pressure ≤ 0.5 bar(g) the oat drain opens
• Closed when pressureless ([NC] normally closed) - the oat drain remains closed even at operating pressure 0 bar(g)
Float drain opens Float drain closes
3
2
1
3
2
1
Both types of drain are delivered with the position >>Automatic discharge<< from the factory. The knurled screw is
screwed downwards as far as it will go.
To test the discharge function or relieve the pressure on the lter during maintenance work, the oat drain can be set to
the position >>mechanically open<<. Screw the knurled screw anti-clockwise (left-hand thread) upwards as far as it will go.
Automatic discharge Mechanically open
INFORMATION Condensate discharge!
i
Condensate discharge depends on the product combination and can vary.
For further information on possible product combinations see “4.3 Product identication” on Page 14.
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4.4.3 Condensate discharge through BEKOMAT
Condensate discharge can also take place via the automatic BEKOMAT® condensate discharge.
More detailed information can be found in the installation and operation manual for the BEKOMAT®.
4.5 Scope of delivery
The following table shows the scope of delivery of the lter.
Figure Description/Explanation
Filter
Installation and operation manual
INFORMATION Possible product combinations!
iThe scope of delivery can vary depending on the product combination.
For further information on possible product combinations see “4.3 Product identication” on Page 14.
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4.6 Type plate
The type plate contains the identication and operating parameters of the lter and is located on the housing.
If you contact the manufacturer or supplier, always have this data ready for system identication.
Example:
Position on rating plate Description
Super Fine Filter BEKO lter designation
Model: Sales designation
Material no. Material number
Lot Lot number
Year Year of manufacturer
Element Filter element type
Element mat-no.: Filter element material number
Min./max. working temperature TS Min./max. operating temperature range
Max.working pressure PS Max. working pressure range
Volume Housing volume
Test pressure PT Test pressure
Connection Thread connections
pipe G 1/2 Thread connection of supply pipe
drain G 1/2 Thread connection of condensate drain
Fluidgroup 2 Fluid group according to Pressure Equipment Directive
2014/68/EU
PED2014/68/EU / Cat. - Specication of the category according to
Pressure Equipment Directive 2014/68/EU
NOTE Handling the type plate!
Never damage, remove or make the type plate illegible.
For more information regarding the symbols printed on the type plate, see “1.4 Explanation of the symbols and
pictograms utilised” on Page 5.
Super Fine filter
Type:
Material-no.:
Lot:
Year:
Element:
Element mat.-no.:
Min./max. working
temperature TS:
Max. working
pressure PS:
Volume:
Test pressure PT:
Connection:
S055SWC
4002851
201725
2017
06S
4002724
+2 ... 60 °C / +35 ... +140 °F
0,3 ... 16 bar / 4.4 ... 232 psi
0,42 l
23 bar / 334 psi
pipe G 1/2
drain G 1/2
Fluidgroup 2
PED2014/68/EU / Cat. -
BEKO TECHNOLOGIES GmbH
beko-technologies.com
Made in Germany
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4.7 Filter element sticker
The lter element can be identied on the basis of a sticker on the base of the lter element.
There are dierent lter elements for dierent applications and degrees of ltration.
4038104
W5822635/002
CLEARPOINT
Flow
04FX (04F,04G)
Made in Germany
1
2
4
6
3
5
Sticker on the base of the lter element Filter element sticker
View lter element base
Position no. Explanation/description
[1] Order number
[2] Lot number
[3] Product group
[4] Direction of ow
[5] 04FX designation of the lter element
[6] 04F, 04G designation of predecessor lter element in brackets
4.8 Maintenance sticker for lter element replacement
The next due lter element replacement date is entered on this sticker. For this, mark the respective month [1] and enter
the year accordingly [2] .
1
2
Position no. Explanation/description
[1] Specication of month for next lter element replacement
[2] Specication of year for next lter element replacement
CLEARPOINT®3eco coalescing lter Installation and operation manual
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