OMEGA AIR CKL User manual

Omega Air User Manual CKL-CHP v3.00 eng
Installation and operating
manual
CKL-CHP compressed air condensate separator
Please read the following instructions carefully before installing cyclone housing unit
into service. Trouble free and safe operating of the unit can only be guaranteed if
recommendations and conditions stated in this manual are respected.

CKL-CHP - Installation and operating manual
2
Description
CKL-CHP condensate separators have been specifically developed for high efficient removal
of bulk liquids from compressed air systems. Inside the housing there is a condensate
separator element. This element separates already liquefied water from mainstream and
prevents the liquids and large particles from being airborne again. To discharge condensate
from the CKL-CHP condensate separator it is essential to install automatic or electronic
condensate drain.
Components
Part
1
Plugs G1/8”
2
Cyclone head
3
Cyclone element
4
O-ring + back-up ring
5
O-ring
6
Cyclone bowl
2
3
4
5
6
1

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Technical data
Housing
size
*Connections
[inch]
CYCLONE
ELEMENT
**FLOW CAPACITY
[Nm3/h] [scfm]
DIMENSIONS [mm]
Volume
[l]
Weight
[kg]
A
B
C
D
CKL-CHP 003
1/4
40
23,5
182
98
104
30
0,19
7,9
CKL-CHP 005
3/8
Integrated
CKL-CHP
Cyclone
element
70
41,2
182
98
104
30
0,20
7,9
CKL-CHP 007
1/2
130
76,5
230
118
129
36
0,40
15,7
CKL-CHP 010
3/4
195
115
254
118
129
36
0,48
16,6
CKL-CHP 018
1
275
162
276
145
158
46
0,76
27,3
CKL-CHP 030
1 1/4
380
223
328
145
158
46
0,98
29,6
CKL-CHP 047
1 1/2
495
291
385
195
216
65
2,2
67,8
CKL-CHP 094
2
715
421
460
195
216
65
2,9
73,5
* BSP (ISO 228-1); NPT (ANSI B1.20.1) on request
**Flow capacity at 7 bar(g), 20°C
CORRECTION FACTORS
To calculate the correct capacity of a given cyclone based on actual operating
conditions, multiply the nominal flow capacity by the appropriate correction
factor(s).
CORRECTED CAPACITY = NOMINAL FLOW CAPACITY x COP
OPERATING PRESSURE
MATERIALS
CHP
IHP
Housing material
Carbon steel (ANSI A-105),
Stainless steel 1.4301 (1.4404 on requet)
Corrosion protection
Chemical nickel plating (25μm)
/
Fittings, Screws
Stainless steel1.4404
Sealing
FKM with PTFE backup ring
Lubricant
Shell cassida grease RLS 2
PRESSURE EQUIPMENT DIRECTIVE PED 2014/68/EU (Fluid group 2)
Size
PED Category
003 - 030
Article 4.3
047
Category 2, Module H
094
Category 3, Module H
Operating temperature
1,5 - 65 °C
35 - 149 °F
Operating pressure
100, 250, 420 bar(a)
0 –1450, 3625, 6091 psi
[bar]
7
25
40
64
100
250
420
[psi]
100
362
580
928
1450
3625
6091
COP
1
3
5
8
12
12
12
B
C
D
A
G 1/4"

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PRESSURE EQUIPMENT DIRECTIVE PED 2014/68/EU (Fluid group 1)
Size
PED Category
003 - 047
Category 3, Module H
094
Category 4, Module H1
There is Technical datasheet available. For additional technical specification, contact
manufacturer.
Safety instructions
The relevant safety at work and accident prevention regulations, plus operating instructions,
shall apply for operating the cyclone. The cyclone has been constructed in accordance with
the generally recognized rules of engineering. It complies with the requirements of directive
PED 2014/68/EU concerning pressure equipment.
Ensure that installation complies with local laws for operation and routine testing of
pressure equipment at the place of installation.
Operator/user of the cyclone should make himself familiar with the function, installation and
start-up of the unit. All the safety information is always intended to ensure your personal
safety.
Do not exceed max. operating pressure or operating temperature range (see data
label).
The permissible working temperatures and pressures for ad-on parts and separator
elements are given under Technical data for those ad-ons. Maximum temperature
and pressure for assembled system is the lowest of any individual part.
It is necessary to ensure that the unit is equipped with the corresponding safety and
test devices to prevent the permissible operating parameters from being exceeded.
Separator has been designed for a primarily static pressure. Rapid changes of
pressure are not allowed.
Ensure that the separator is not subject to vibrations that could cause fatigue
fractures.
Separator is not to be subjected to mechanical stresses.
The medium used may not have any corrosive components that could attack the
materials of the separator in a way that is not permitted. Do not use the separator in
hazardous areas with potentially explosive atmospheres.
All installation and maintenance work on the separator may only be carried out by
trained and experienced specialists.
It is forbidden to carry out any kind of work on the cyclone, including welding and
constructional changes, etc.

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A pressure gauge, which shows the operational pressure, must be installed in the
unit, respectively in the pipeline.
Depressurize the system before carrying out the installation work. The unit must be
installed vertically in the piping.
Ensure that separator is installed without any stresses.
Use original spare parts only.
Use the device for appropriate purpose only.
Appropriate use
CKL-CHP series cyclone separators are designed for high efficient removal of bulk
liquids from compressed air and vacuum systems. This appliance must be used
only for the purpose for which it was specifically designed. All other uses are to be
considered incorrect and will void warranty.
Specifically:
cyclone can only be used for “GROUPE 2” fluids (PED 2014/68/EU).
cyclone can not be used for explosive, toxic, flammable, corrosive and “GROUPE 1”
fluids (PED 2014/68/EU).
Warning: internal corrosion can seriously reduce the safety of installation: check it during
changing the cartridge.
The manufacturer will under no circumstances be responsible for any damage resulting from
improper, incorrect or unreasonable use.
Use genuine spare parts only. Any damage or malfunction caused by the use of ungenuine
parts is not covered by Warranty or Product Liability.

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Installation
1p=0 bar
2
3
4
5
1.
2.
6
7
O-ring
back-up ring
8
1.
2.
9
10
1. 2.

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Cyclone can be hand over to market and operation only in case, if it is properly installed and
used for intended purpose. Installation must not be dangerous for health and safety of
people. Cyclone must be installed to solid and levelled ground by support legs (if necessary
fixing with bolts). There must be enough space for undisturbed inspection and maintenance.
Cyclone must ensure safety and reliably operation. Cyclone must be protected against
injuries and non-authorized substitution. Operating pressure must correspond to design
pressure. Cyclone must be connected to pipeline with controlled pressure, which cannot
exceed values of the max. working (operating) pressure.
Cyclone must have all necessary technical documentation. It must be regularly checked and
maintained in accordance with technical and state regulations. Instructions for handling in
the case of emergency must hang on the visible place near the vessel. In case of explosion,
operating process must be stopped immediately.

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Maintenance
To prevent air leakage and malfunction replace housing O-ring if necessary. For
replacement contact manufacturer.
Damaged components are to be replaced by new ones. If a marked degree of
damage is found, the entire cyclone is to be replaced.
Cyclone has been designed for a life of 10 years in normal operating environment.
After 10 years periodical checks of cyclone integrity are strongly recommended for
safe operation.
Carry out a check for leaks once the maintenance work has been finished.
Warranty exclusion
The guarantee shall be void if:
The operating instructions were not followed with respect to initial commissioning
and maintenance.
The unit was not operated properly and appropriately.
The unit was operated when it was clearly defective.
Non-original spare parts or replacement parts were used.
The unit was not operated within the permissible technical parameters.
Unauthorised constructional changes were made to the unit or if parts of the unit
that may not be opened were dismantled.
OMEGA AIR d.o.o. Ljubljana
Cesta Dolomitskega odreda 10
SI-1000 Ljubljana, Slovenia
Tel.: [phone]
Fax.: [phone]
E-mail: [email protected]
www.omega-air.si