Assembly and Maintenance manual according to regulation DIN 82079

Transcription

1 Assembly and Maintenance manual according to regulation DIN MTROC Version 4.16 Part 1 Information to the manufacturer Giebel FilTec GmbH Carl-Zeiss-Str. 5 DE Bretzfeld-Schwabbach Tel. +49 (0) Fax +49 (0) info@giebel-adsorber.de Part 2 Adsorber overview mt 200-PA, mt 210-PA, mt 220-PA, mt 230-PA mt 300-PA, mt 310-PA, mt 320-PA, mt 330-PA mt 500-PA, mt 510-PA mt 310-MA, mt 330-MA, mt 510-MA Used materials: Acrylic glass, Aluminum, Stainless steel, Acrylonitrile butadiene rubber (NBR), fluororubber (FKM), Silica gel (Amorphous silicon dioxide), Active carbon (form coal), Ethylene propylene diene rubber (EPDM) REACH note: No disclosure requirement according to Regulation (EC) No. 1907/2006. GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 1/9

2 Part 3 Build up and materials Adsorber part PA Adsorber part mt 201-PA, mt 221-PA, mt 301-PA mt 321-PA, mt 501-PA Adsorber part mt 211-PA, mt 231-PA, mt 311-PA mt 331-PA, mt 511-PA Use Disposable Reusable Housing material Acrylic glass Acrylic glass / Aluminium Adsorbents Silica gel, Active carbon Silica gel, Active carbon filter disc Particle filter Sealing Operating temp. Pleated filter unit with 3 µm separation NBR / FKM -40 C C Adsorber part MA Verwendung Gehäusewerkstoff Adsorptionsmittel Partikelfilter Dichtwerkstoff Betriebstemperatur Adsorberteil mt 311-MA, mt 331-MA, mt 511-MA Reusable Aluminium Silica gel, Active carbon filter disc Pleated filter unit with 3 µm separation NBR / FKM / EPDM -40 C C Connection PA & MA Connection Connection Material Sealing Inch Aluminium NBR / FKM / EPDM GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 2/9

3 Part 4 Technical data MTROC PA mt 200-PA mt 210-PA mt 220-PA mt 230-PA mt 300-PA mt 310-PA mt 320-PA mt 330-PA mt 500-PA mt 510-PA Total weight [kg] 1,0 1,1 1,3 1,5 1,8 2,0 2,6 2,8 3,6 3,9 Adsorbents [kg] 0,3 0,3 0,5 0,5 0,8 0,8 1,3 1,3 1,9 2,0 Height [mm] Housing diameter [mm] Screw diameter [mm] Connection Valves Valve flaps G 1" M. (SW36) G 1" M. (SW36) MTROC MA mt 310-MA mt 330-MA mt 510-MA Total weight [kg] 2,5 3,4 4,9 Adsorbents [kg] 0,9 1,4 2,2 Height [mm] Housing diameter [mm] Screw diameter [mm] Connection Valves Valve flaps G 1" M. (SW36) GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 3/9

4 Part 5 Assembly and comissioning Proceed to assemble the entire adsorber as follows: 1. Turn off the system. 2. Screw the connection on the system. 3. Remove the protective lamination on the bottom of the adsorber part. 4. Screw the adsorber part on the connection. Part 6 Maintenance Procedure for reusable adsorbers 1. Turn off the system. 2. Removing the adsorber part by screwing off from the connection. 3. Remove the cover by opening the clamps. 4. Remove the gasket inside the cover and replace it with new one. 5. Remove activated carbon disc and empty desiccant. 6. Pull out the dust filter. 7. Also remove the lower foam disc. 8. Install new foam disc. 9. Insert the new dust filter and then fill in fresh desiccant. While filling in of the desiccant easily beat with a soft object (eg thenar) against the housing to compress the silica gel bulk. 10. Insert new activated carbon disc and then close the cover by locking the clamps. 11. Screw the adsorber part back on the connection. Procedure for disposable adsorbers 1. Turn off the system. 2. Removing the adsorber part by screwing off from the connection. 3. Screw the new adsorber part back on the connection. GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 4/9

5 Part 7 Spare parts and storage ADSORBER mobiltroc 200-PA mobiltroc 210-PA mobiltroc 220-PA mobiltroc 230-PA mobiltroc 300-PA mobiltroc 310-PA DISPOSABLE ADSORBER PART Adsorber part mt 201-PA Adsorber part mt 221-PA Adsorber part mt 301-PA REUSABLE SPARE PARTS KIT Spare parts kit mt 213-PA Spare parts kit mt 233-PA Spare parts kit mt 313-PA Adsorber part Build up - Adsorbents - Active carbon - Filter unit - Sealing Pre-assembled in the housing and air tight packed. mobiltroc 320-PA Adsorber part mt 321-PA mobiltroc 330-PA Spare parts kit mt 333-PA mobiltroc 500-PA mobiltroc 510-PA mobiltroc 310-MA mobiltroc 330-MA mobiltroc 510-MA Adsorber part mt 501-PA Spare parts kit mt 513-PA Spare parts kit mt 313-MA Spare parts kit mt 333-MA Spare parts kit mt 513-MA Spare parts kit Content - Adsorbents - Active carbon filter discs - Filter unit complete - Sealings Single and air tight packed. Desiccant individually Content - Adsorbents Air tight packed. Order of replacement parts For a permanent operational readiness of the absorber and thus the hydraulic power unit and the transmission, make sure that there is always a spare parts package or a replacement adsorber in stock. The time until complete color change from orange to green and thus the service life of the adsorber will depend on several factors: - Number and duration of flow passage and treatment intervals. - Air flow volume and flow velocity, relative humidity of the ambient air. - Temperature of the ambient air and the medium to be ventilated. Storage of adsorbers All filled with desiccant modules are packaged airtight. Additionally the desiccant should be stored in dark and dry places at -10 C to +30 C to prevent damage. GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 5/9

6 Part 8 Regeneration and disposal New / Regenerated Observe color change Orange - Green Dispose / Regenerate New / Regenerated Observe color change Orange - Colorless Dispose / Regenerate New / Regenerated Observe color change Blue - Pink Dispose / Regenerate Regeneration In practice, the most common method used to regenerate silica gel is to increase the temperature. For desorption of water vapor from silica gel, the temperature level has to be above 100 C. Recommended for regeneration are temperatures between 150 C to 175 C. However, bearing in mind that the color indicator plated on to the silica gel can be damaged at these temperatures. Therefore, a regeneration temperature is specified at a level of 121 C for silica gel with color indicator and should not exceed 140 C. Disposal After completion of the useful life, the device should be disposed in accordance with the relevant statutory provisions. Metal and plastic parts should be separated and disposed. The loaded desiccant can be disposed of with household waste. Silica gel is not classified as dangerous according to European Union legislation (Regulation EC No. 1272/2008). According to EC Directives (67/548 / EEC and 1999/45 /EC) it does not require labeling. Silica gel does not belong to the health and environmentally hazardous substances. The desiccant silica gel is blue mixed with Cobalt (II) chloride hexahydrate and is classified in accordance with EC Directive (1999/45 / EC) as requiring labeling substance. This desiccant is one of the health and environmentally hazardous substances. When disposing the national laws must be observed. GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 6/9

7 Part 9 Risk and hazard analysis 1 Overpressure resp. vacuum builds up inside the system 1.1Valve flap are jammed / blocked The functionality may be affected by contamination. See Maintenance Schedule Item Too high air flow At an excessively high air flow, overpressure resp. vacuum can be build up inside the system 1.3 Filter contaminated The filter unit may be clogged with dirt particles. See Maintenance Schedule Item Oil on the desiccant Oil particles collect in the pores of the silica gel. In the film of oil, dirt particles can accumulate and thus hinder the supply and exhaust air. See Maintenance Schedule Item 1 2 Moist air flows into the system 2.1 Porous sealings Moist air can flow inside the adsorber at porous areas. Thus no complete drying is possible and moist air is entering the system. See Maintenance Schedule Item Saturated desiccant If the desiccant is saturated, it can t longer adsorb moisture. Thus moist air is entering the system. See Maintenance Schedule Item Too high air flow At an excessively high air flow, the contact time between moist air and desiccant is too low. This allows moist air to flow into the system. 2.4 Oil on the desiccant If oil particles get into the adsorber, the particles close the pores of the desiccant. Thus no adsorption is possible. See Maintenance Schedule Item Ambient temperature too high Does the peripheral temperature rises more than 80 C, the inflowing ambient air is dried only partially. 3 Adsorber housing is damaged 3.1 Material resistance When selecting an adsorber the ambient and operating conditions should be respected. See Maintenance Schedule Item Temperature range The ambient and operating temperatures should not exceed the specified range or below, otherwise the adsorber can be damaged. See Maintenance Schedule Item Pressure range The adsorber isn t construed for overpressure resp. vacuum above 0,5 bar. See Maintenance Schedule Item 5 GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 7/9

8 3.4 Improper handling In the choice of material of the absorber operating conditions (environmental factors and handling) should be considered. See Maintenance Schedule Item 5 Part 10 Maintenance schedule Cycle 1. Visual inspection of the silica gel to saturation By visual inspection of the adsorber the loading condition of the silica gel can be determined. The color orange indicates that the silica gel can adsorb more water and air is dehumidified. If the silica gel is fully saturated, the color changes to green. If oil particles are placed on the silica gel, the pores are closed and the adsorption capacity is reduced. Thus, the silica gel changes color more slowly and unevenly. The silica gel is removed from the adsorber. New Silica Gel is filled in again. For disposable adsorbers the entire adsorber part is changed. Proceed as described in "Part 6 Maintenance". 2. Inspect Filter unit regarding contamination Remove the cover from the adsorber part and empty the activated carbon disc. Thereafter, drain the desiccant. Subsequently, the filter unit can be removed. The filter unit has to be checked for contamination and should be free from dirt for operating smoothly. The filter unit is part of the spare parts kit and should be replaced with existing pollution. Proceed as described in "Part 6 Maintenance". 3. Check sealings for wearing The sealings and O-rings plugged inside the adsorber and the connection has to be checked for their proper condition. For this, the gasket in the cover, the O-rings of the filter unit, and the O-rings of the connection should be examined for brittleness. For existing damage the sealings and O-rings should be replaced. These are part of the spare parts kit. Proceed as described in "Part 6 Maintenance". Weekly Half-yearly Annually GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 8/9

9 4. Check valve flaps for jamming The adsorber part is visually checked for contamination and damage. To ensure the long term functioning of the valve flap inside the adsorber part they should be inspected. Remove the adsorber part off the connection and check valve flap for patency. If the valves won t open and close, the adsorber part has to be replaced by a new one in order to ensure the full functioning. 5. Visual inspection of the adsorber The adsorber (adsorber part and connection) is visually checked for damage. Damage may occur due to different environmental or operating conditions. If the adsorber is damaged, the damaged part should be replaced to ensure full functionality. 6. Replacement of the wearing parts The wearing parts of the absorber and the connection must be verified on their condition. Regardless of the result of the examination, it is recommended to replace the wearing parts by use of the spare parts kit or a new adsorber part to ensure a smooth operation. Two-yearly Weekly Two-yearly GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 9/9