Beko CLEARPOINT S040 User manual

en
CLEARPOINT® water separator
08-359
Installation and operation manual
> S040
> S050
> S075
> M010
> M015
> M020
> M022
> M025
> M030

Table of contents
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 operating company ...............................................................................................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 Water separation.............................................................................................................................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 Stamp on water separator insert.............................................................................................................20
5. Technical data ............................................................................................................................... 21
5.1 Separator performance data ....................................................................................................................21
5.2 Materials .......................................................................................................................................................23
6. Dimensions.................................................................................................................................... 24
7. Assembly ....................................................................................................................................... 26
7.1 Warning notices ..........................................................................................................................................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 notices ..............................................................................................................................30
9.2.2 Cleaning work ..................................................................................................................................31
9.3 Visual inspection.........................................................................................................................................31
9.4 Replace the oat drain...............................................................................................................................32
9.5 Replacing the water separator insert.....................................................................................................36
9.6 Leakage test .................................................................................................................................................39
10. Decommissioning ....................................................................................................................... 40
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11. Disassembly ................................................................................................................................ 41
11.1 Warning notices........................................................................................................................................41
11.2 Disassembly work.....................................................................................................................................42
12. Disposal....................................................................................................................................... 44
12.1 Warning notices........................................................................................................................................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. Fault and trouble shooting / 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 malfunction and device failure can occur.
1.3 Other applicable documents
This manual contains all the necessary steps for installation and operation of the CLEARPOINT® water separator.
More detailed information about the installation and operation of the accessories is contained in the following
installation and operation manual:
• BEKOMAT® 20
• BEKOMAT® 20 Vario
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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
Note the 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 label)
Note the installation and operating manual
(This symbol is only located on the type plate)
Maintenance label
This adhesive label shows in a stylised way that the installation and operation manual must
be read before maintenance work is carried out and that the product must be depressurised
before maintenance work.
Flow
Stamp on water separator insert
(This stamp is located on the bottom of the water separator insert and provides information
about the direction of ow.
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1.5 Intended use
CLEARPOINT® water separator and accessories
The CLEARPOINT®water separator, also referred to as separator below, is used for separating drops of liquid 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 users and the environment.
• Only use separators and accessories within the operating parameters given in the technical data and the agreed
delivery conditions.
• Only use separators and accessories within pipework designed for the technical data with appropriate connections,
pipe diameters and assembly clearance.
• Only use separators 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 separators and accessories in non-explosive hazardous areas.
• Only use separators and accessories away from direct solar radiation and heat sources as well as areas subject to
frost.
• Only combine the separators and accessories with the products named and recommended by
BEKO TECHNOLOGIES GMBH in the manual.
Before using the separators, the operating company must make sure that all conditions and prerequisites for intended
use are given.
The separator 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 separators 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 malfunction 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 separator or accessories which are not listed here, the manufacturer must be
informed immediately.
1.7 Legal warranty and liability for property defects
The operating company and user must take into account the intended use. The operating company and user 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 separator is not operated according to the intended use
or is operated outside the specications given in the technical data.
This includes:
• inappropriate technical installation, commissioning, servicing, maintenance or operation
• the use of defective components
• non-compliance with the safety-relevant information, procedure 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 skilled technical personnel listed below who are involved with work on the separator or the
accessories.
INFORMATION Personnel requirements
iThe personnel may not execute any actions on the separator 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 operating company
The responsible operating company must ensure the following to prevent accidents, faults 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 fully operable 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 hazard
Consequences of non-compliance: Death or serious personal injury
WARNING Imminent hazard
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 parameters 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 drains.
• 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, malfunction and device
failure 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.
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 parameters, 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®water separators are designed for the separation of drops of liquid and solid particles in compressed gas
systems.
The condensate accumulated during separation can be discharged manually or automatically.
4.2 Product overview
The separator is made up of the following components:
4
5
7
8
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
3
1
2a
Position no. Explanation/description
[1] Inlet on the separator head
[2] Outlet on the separator head marked additionally by 2a
[3] Housing head
[4] Water separator insert (WS-insert)
[5] Safety slide with locking screw
[6] Type plate
[7] Housing body
[8] Maintenance label
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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
separator component and is divided into the following categories:
[1] = Size: Housing
[2] = WS-insert
[3] = Attachment components top
[4] = Attachment components bottom
The product designation is explained below using the example “S040WWB”:
S040WWB
2
2
3
3
4
4
1
1
Attachment
components
bottom
Attachment
components top
WS insert
Size: Housing S040
S050
S075
M010
M015
M020
M022
M025
M030
W
B
F
W
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Attachment components top
Position no. Letter code Designation
[3] W Without indicator unit
Water separator inserts
Position no. Letter code Designation
[2] W Water separator
Position no. Model series Construction size Designation
[1]
S 040
Housing size
S 050
S 075
M 010
M 015
M 020
M 022
M 025
M 030
Attachment components bottom
Position no. Letter code Designation
[4] B BEKOMAT®20
F Float drain, open when pressureless (NO - normally open)
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4.4 Function description
4.4.1 Water separation
The compressed gas enters the water separator through the inlet on the separator head [1]. A specially shaped spin
insert [2] makes the compressed gas start rotating quickly. The resulting centrifugal forces press the condensate
particles against the outer wall of the housing. Gravity makes the condensate particles ow downwards into the
collecting space [3] from where they are discharged.
1
2
3
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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 container 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 container.
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 oat 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 separator 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!
iCondensate 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 drain.
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 separator.
Illustration Description/Explanation
Separator
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 separator 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 type plate Description
Water separator BEKO separator designation
Model: Sales designation
Material no. Material number
Lot Lot number
Year Year of manufacturer
Element Water separator insert
Element mat-no.: Material number water separator insert
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.
Water separator
Type:
Material-no.:
Lot:
Year:
Element:
Element mat.-no.:
Min./max. working
temperature TS:
Max. working
pressure PS:
Volume:
Test pressure PT:
Connection:
S050WWF
4004363
201851
2018
04W
4004320
+2 ... 60 °C / +35 ... +140 °F
1,5 ... 16 bar / 22 ... 232 psi
0,31 l
23 bar / 334 psi
pipe G 3/8
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 Stamp on water separator insert
The WS-insert can be identied by means of a stamp on the bottom of the element.
1
Flow
Stamp on the bottom of the WS-insert Stamp on water separator insert -
View of the bottom of the element
Position no. Explanation/description
[1] Direction of ow
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