Omega GCF User manual

3401786-GCF-OmegaAir_eng_v1.00_ver16082016
Installation and operating
manual
GCF compressed gas filter
Please read the following instructions carefully before installing filter into service. Trouble
free and safe operating of the filter can only be guaranteed if recommendations and
conditions stated in this manual are respected.
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GCF - Installation and operating manual
2
Components
Part
1
Head cover
2
Filter head
3
Housing sealing
4
Filter element
5
Filter bowl
6
Sight window (optional)
4
3
5
1
2
6
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GCF - Installation and operating manual
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Technical data
Housing
size
Connections
[inch]
FILTER
ELEMENT
FLOW CAPACITY
DIMENSIONS [mm]
WEIGHT
[kg]
Volume
[l]
[Nm3/h]
[scfm]
A
B
C
D
GCF 20
3/8
20 C
72
42
187
88
20
80
0,7
0,47
GCF 21
1/2
21 C
96
56
256
88
20
80
0,8
0,6
GCF 30
1/2
30 C
150
88
278
106
25
100
1,3
1,2
GCF 31
3/4
31 C
216
127
278
106
25
100
1,3
1,2
GCF 40
1
40 C
282
166
252
125
32
120
2,1
1,57
GCF 41
1
41 C
360
212
352
125
32
140
2,4
2,2
GCF 42
1 ¼
42 C
432
254
352
125
32
140
2,4
2,2
GCF 43
1 ½
43 C
510
300
450
125
32
160
3,2
3,0
GCF 44
1 ½
44 C
750
441
450
125
32
160
3,2
3,0
GCF 50
2
50 C
888
522
605
160
43
180
5,1
6,0
GCF 51
2
51 C
1176
692
605
160
43
180
5,1
6,0
GCF 52
2 ½
52 C
1440
847
685
160
43
200
6,3
6,5
GCF 60
3
60 C
1968
1158
800
240
60
300
12,9
19
GCF 61
3
61 C
2760
1624
800
240
60
300
12,9
19
Flow capacity at 7 bar(g), 20°C
MATERIALS
Housing material
Aluminum
Fittings, Screws
Brass, Brass-zinc plated, Steel
Cover
ABS
Sealing
Viton
Corrosion protection
Anodized (optional)
Outside protection
Powder paint coated (Epoxi-polyester base)
Lubricant
Shell cassida grease RLS 2
CORRECTION FACTORS
To calculate the correct capacity of a given filter based on actual operating
conditions, multiply the nominal flow capacity by the appropriate correction factor(s).
CORRECTED CAPACITY = NOMINAL FLOW CAPACITY x COP
[bar]
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
[psi]
29
44
58
72
87
100
115
130
145
160
174
189
203
218
232
247
261
276
290
COP
0,38
0,5
0,63
0,75
0,88
1
1,13
1,25
1,38
1,50
1,63
1,75
1,88
2,00
2,13
2,25
2,38
2,50
2,63
Operating temperature
1,5 - 65 °C
35 - 149 °F
Operating pressure
0 - 20 bar(g)
0 - 290 psi
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PRESSURE EQUIPMENT DIRECTIVE PED 2014/68/EU
(Fluid group 1)
(Fluid group 2)
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 filter. The filter has been constructed in accordance with the
generally recognized rules of engineering. It complies with the requirements of directive
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 filter 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 filter
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.
•Filter has been designed for a primarily static pressure. Rapid changes of pressure are
not allowed.
•Ensure that the filter is not subject to vibrations that could cause fatigue fractures.
•Filter is not to be subjected to mechanical stresses.
GCF 20 - GCF 31
Not required
GCF 40 - GCF 42
Category 1, Module A
GCF 43 - GCF 52
Category 2, Module H
GCF 60 - GCF 61
Category 3, Module H
GCF 20 - GCF 42
Not required
GCF 43 - GCF 52
Category 1, Module A
GCF 60 - GCF 61
Category 2, Module H
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GCF - Installation and operating manual
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•The medium used may not have any corrosive components that could attack the
materials of the filter in a way that is not permitted. Do not use the filter in
hazardous areas with potentially explosive atmospheres.
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GCF - Installation and operating manual
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•All installation and maintenance work on the filter may only be carried out by trained
and experienced specialists.
•It is forbidden to carry out any kind of work on the filter and piping, including welding
and constructional changes, etc.
•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 filter is installed without any stresses.
•Use original spare parts only.
•Use the device for appropriate purpose only.
Appropriate use
GCF filter housings have been developed for high efficient removal of solid
particles, water, oil aerosols, hydrocarbons and odour vapours from compressed
gas systems. This appliance must be used only for the purpose for which it was
specifically designed. All other uses are to be considered incorrect.
Specifically:
•filter is not intended for human breathing without proper additional equipment.
•filter can be used for “GROUPE 1” natural gas (2014/68 EU),
•for other gases contact manufacturer
•filter can also be used for “GROUPE 2” fluids (2014/68 EU).
Warning: internal corrosion can seriously reduce the safety of installation: check it during
changing the cartridge.
The manufacturer cannot be held 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
Operations should be performed only by qualified personnel. Never operate with
installation under pressure. The user is responsible to ensure that the filter will never
operate at pressure exceeding the nominal values. Eventual over-pressure could be
dangerous and hazardous to the operator and the equipment.
The filter assembly and installation procedures are as follows:
•If provided, install the pressure drop indicator or the Differential Pressure Gauge
(optional) on the filter head.
•Connect the filter head to the compressed gas piping and check that the gasflow
corresponds to the direction of the arrow positioned on the filter head cap.
•Clean accurately the piping and the filter head outlets, remove any shaving, slaver or
scrap from tooling.
•Lubricate the O-ring and the sealing surfaces of the filter head and cartridge, use
multipurpose grease (SILICONE FREE).
•Fit the filter cartridge on the filter head by screwing it in the housing. Tightness is
ensured by one o-ring.
•Fit the filter bowl and tight it accurately.
•Filters must always be installed in a vertical position with sufficient space around. The
minimum distance (D in the technical data table) has to be assured under the filter
bowl, which is necessary for filter cartridge changing.
•Stick the adhesive label showing the month and year for the next filtering element
change (max. one year) on the filter bowl.
•Slowly pressurize the installation and check it for gas leakage.
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Starting up
•Check that the operating data (pressure, temperature and flow-rate) do not exceed
values on the specification plate.
•Close the on-off valve (V1) downstream of the filter, slowly open the on-off valve (V2)
upstream to the filter, and let the gas flow from the manual or automatic drain valve
for a few minutes; close the drain valve and slowly open the on-off valve (V1) down-
line from the filter.
If a filter grade A is installed, check the good efficiency of the pre-filters, otherwise the
presence of any oil and water aerosols make the absorption power of the filter void.
V2
V1
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Maintenance
Filter elements are subject to wear. In order to maintain system efficiency, optimal
performance and best gas quality, these rules of proper maintenance should be followed:
•Replace filter elements P, R, M, S at least once per year or when pressure drop
reaches 350mbar.
•A filter element must be changed after 6 months.
•B filter element can be cleaned with ultrasonic bath or with back flushing. Intervals of
cleaning depend on application. If necessary replace filter element with new one.
•The housing O-ring can be damaged during filter element change. To prevent gas 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 filter is to be replaced.
•Filter has been designed for a life of 10 years in normal operating environment. After 10
years periodical checks of filter 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.
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3401786-GCF-OmegaAir_eng_v1.00_ver16082016
OMEGA AIR d.o.o. Ljubljana
Cesta Dolomitskega odreda 10
SI-1000 Ljubljana, Slovenia
Tel.: [phone]
Fax.: [phone]
E-mail: [e-mail]
www.omega-air.si
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