Assembly and Maintenance manual according to regulation DIN 82079

Transcription

1 Assembly and Maintenance manual according to regulation DIN VARIO VG 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 300-PA, 310-PA, 320-PA, 330-PA, 500-PA, 510-PA 520-PA, 530-PA, 550-PA, 560-PA Used materials: Acrylic glass, Aluminium, Acrylonitrile butadiene rubber (NBR), fluororubber (FKM), Silica gel (Amorphous silicon dioxide), Active carbon (form coal) 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 301-PA, 321-PA 501-PA, 521-PA 551-PA Adsorber part 311-PA, 331-PA 511-PA, 531-PA 561-PA Use Disposable Reusable Housing material Acrylic glass Acrylic glass / Aluminium Adsorbents Silica gel, Active carbon bulk Silica gel, Active carbon bulk Particle filter Sealing Operating temp. Pleated filter unit with 3 µm separation NBR / FKM -40 C C Receiving part PA Connection Housing material Sealing Receiving part DV 3-MA, DV 5-MA Inch Aluminium NBR / FKM Part 4 Technical data VARIO VG 300-PA 310-PA 320-PA 330-PA 500-PA 510-PA 520-PA 530-PA 550-PA Total weight [kg] 2,0 2,3 2,8 3,0 3,7 4,0 5,5 5,7 6,5 6,7 Silica gel weight [kg] 0,2 0,2 0,4 0,4 0,5 0,5 0,9 0,9 0,9 0,9 Active carbon weight [kg] 0,5 0,5 0,8 0,8 1,0 1,1 1,9 1,9 2,8 2,8 Height [mm] Housing diameter [mm] Screw diameter [mm] Connection G 3/4" M. (SW27) G 3/4" M.(SW27) G 3/4" M. (SW27) G 3/4" M. (SW27) Valves [IN-OUT] PA GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 2/9

3 Part 5 Assembly and comissioning Proceed to assemble the entire adsorber as follows: 1. Turn off the system. 2. Screw the receiving part on the system. 3. Place the O-Ring inside the provided groove of the receiving part and check for correct seating. 4. Remove securing clips off the receiving part. 5. Remove the protective lamination on the bottom of the adsorber part. 6. Attach the adsorber part on the sleeve of the receiving part. 7. Hook the tensioning clamps into the locking hook and press the tensioning clamps down. 8. Secure the tensioning clamps with the securing clips. Part 6 Maintenance Procedure for reusable adsorbers 1. Turn off the system 2. Removing the adsorber part by opening the tensioning clips. 3. Open the cover and remove it from the adsorber. 4. Remove the gasket inside the cover and replace it with new one. 5. Empty the active carbon and pull out the dust filter. 6. Also remove the silica gels and the foam discs. 7. Install new foam disc and fill in silica gel orange. 8. Install next foam disc and fill in silica gel colorless. 9. Install the third foam disc as well as the dust filter. 10. Afterwards fill in new active carbon. While filling in easily beat with a soft object (eg thenar) against the housing to compress the bulk. 11. Replace O-rings between the receiving part and adsorber part. 12. Clean lower foam disc if necessary with compressed air. 13. Place the adsorber part back to the receiving part and close the tensioning clamps. Procedure for disposable adsorbers 1. Turn off the system. 2. Removing the adsorber part by opening the tensioning clamps. 3. Replace O-ring between the receiving part and adsorber part. 4. Clean lower foam disc if necessary with compressed air. Place the new adsorber part back to the receiving part and close the tensioning clamps. GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 3/9

4 Part 7 Spare parts and storage ADSORBER DISPOSABLE ADSORBER PART REUSABLE SPARE PARTS KIT DUO-VARIO VG 300-PA DUO-VARIO VG310-PA DUO-VARIO VG 320-PA DUO-VARIO VG 330-PA DUO-VARIO VG 500-PA DUO-VARIO VG 510-PA DUO-VARIO VG 520-PA DUO-VARIO VG 530-PA Adsorber part 301-PA Adsorber part 321-PA Adsorber part 501-PA Adsorber part 521-PA Spare parts kit 313-PA Spare parts kit 333-PA Spare parts kit 513-PA Spare parts kit 533-PA Adsorber part Build up - Desiccant - Active carbon - Filter unit - Sealing Pre-assembled in the housing and air tight packed. DUO-VARIO VG 550-PA Adsorber part 551-PA DUO-VARIO VG 560-PA Spare parts kit 563-PA Spare parts kit Content - Adsorbents set - Foam discs - Filter unit complete - Sealings Single and air tight packed. Desiccant individually Content - Adsorbents set Air tight packed. Order of replacement parts For a permanent operational readiness of the adsorber and thus the gear resp. the hydraulic unit, make sure that there is always a spare parts package or a replacement adsorber in stock. The time until complete saturation of the activated carbon by adsorbing oil aerosols and thus the service life of the adsorber will depend on several factors: - Number and duration of flow passage and treatment intervals. - Amount of exhausted oil particles and oil aerosols. 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 4/9

5 Part 8 Disposal New / Regenerated Observe color change Orange - Colorless Dispose / Regenerate New Observe oil increase Replace Adsorber part / Adsorbents set Regeneration The regeneration of the loaded silica gel and activated carbon is possible only under special conditions and is therefore not recommended. 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 silica gel and activated carbon can be disposed of with household waste. Silica gel and activated carbon 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. GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 5/9

6 Part 9 Risk and hazard analysis 1 Overpressure resp. vacuum builds up inside the system 1.1 Too high air flow At an excessively high air flow, overpressure resp. vacuum can be build up inside the system. 1.2 Filter contaminated The filter unit may be clogged with dirt particles. See Maintenance Schedule Item Prefilter disc contaminated The prefilter disc may be clogged with dirt particles. See Maintenance Schedule Item Active carbon oversaturated After the activated carbon is fully saturated, oil may accumulate and clog the adsorber. 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 parts. 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 Vibrations of the system Excessive vibration of the system may damage the adsorber. See Maintenance Schedule Item 6 GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 6/9

7 3.3 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 Improper handling In the choice of material of the absorber operating conditions (environmental factors and handling) should be considered. See Maintenance Schedule Item 6 4 Oil mist flows from the adsober 4.1 Saturated active carbon If the activated carbon is fully saturated by the outflowing oil particles they exhaust into the ambient air. See Maintenance Schedule Item 2 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 colorless. 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. Visual inspection of the active carbon to saturation By visual inspection of the adsorber, the loading condition of the active carbon is to be determined. The colorless silica gel indicates that more oil particles can be adsorbed. If the active carbon is fully saturated, the silica gel changes color from colorless to white/brown. The activated carbon and desiccant has to be removed from the adsorber. New activated carbon and desiccant is filled in again. For disposable adsorbers the entire adsorber part has to be changed. Proceed as described in "Part 6 Maintenance". Weekly Weekly GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 7/9

8 3. Inspect Filter unit regarding contamination Remove the cover from the adsorber part and empty the active carbon. Afterwards, 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". 4. Check prefilter disc for contamination The prefilter disc should be checked for contamination, which can enforce clogging and prevent the free entry of air. The prefilter disc has to be removed and cleaned with compressed air to remove dirt particles and dust. 5. Check sealings for wearing The sealings and O-rings plugged inside the adsorber and the receiving part 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 between the receiving and the adsorber part 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". 6. Visual inspection of the adsorber The adsorber (receiving part and adsorber part) 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. Half-yearly Half-yearly Annually Weekly GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 8/9

9 7. Replacement of the wearing parts The wearing parts of the absorber and the receiving part 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 GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 9/9