Assembly and Maintenance manual according to regulation DIN DV TB 310-MA, DV TB 330-MA DV TB 510-MA, DV TB 530-MA DV TB 560-MA

Transcription

1 Assembly and Maintenance manual according to regulation DIN VARIO TB 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 310-MA, 330-MA 510-MA, 530-MA 560-MA 310-ME, 330-ME 510-ME, 530-ME 560-ME Used materials: Acrylic glass, Aluminium, Stainless steel, Acrylonitrile butadiene rubber (NBR), Polycarbonate, 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 1/11

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 Acrylic glass / Polycarbonate Acrylic glass / Aluminium / Polycarbonate Adsorbents Silica gel, Active carbon bulk Silica gel, Active carbon filter disc Particle filter Operating temp. Dust filter disc with 2 µm separation -40 C C Adsorber part MA Use Adsorbents Particle filter Operating temp. Adsorber part 311-MA, 331-MA, 511-MA, 531-MA 561-MA Reusable Aluminium Silica gel, Active carbon filter disc Dust filter disc with 2 µm separation -40 C C Adsorber part ME Use Adsorbents Particle filter Operating temp. Adsorber part 311-ME, 331-ME, 511-ME, 531-ME 561-ME Reusable Stainless steel Silica gel, Active carbon filter disc Dust filter disc with 2 µm separation -40 C C Connection part DIN L DIN DIN A DIN B Connection Top 3L-Flange Top thread G1 ¼ Aluminium / Stainless steel Sideways oval flange 80x45 acc. to DIN 2558 Top oval flange 80x45 acc. to DIN 2558 GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 2/11

3 Receiving part PA & MA Connection Receiving part 3-MA, 5-MA Inch Aluminium Receiving part ME Connection Receiving part 3-ME, 5-ME Inch Stainless steel GIEBEL FilTec GmbH Web Tel +49 (0) Seite 3/11

4 Part 4 Technical data VARIO TB-PA 300-PA 310-PA 320-PA 330-PA 500-PA 510-PA 520-PA 530-PA 550-PA Total weight [kg] 3,3 3,6 4,1 4,3 5,6 5,8 7,3 7,4 8,7 9,0 Adsorbents [kg] 0,9 1,0 1,6 1,5 2,1 2,1 3,5 3,3 4,6 4,6 Height [mm] Housing diameter [mm] Outside diameter [mm] PA Connection DIN DIN DIN A DIN B Valves [IN-OUT] VARIO TB-MA 310-MA 330-MA 510-MA 530-MA 560-MA Total weight [kg] 3,5 4,5 6,5 8,2 10,0 Adsorbents [kg] 1,0 1,6 2,4 3,5 4,8 Height [mm] Housing diameter [mm] Outside diameter [mm] Connection DIN DIN DIN A DIN B Valves [IN-OUT] VARIO TB-ME 310-ME 330-ME 510-ME 530-ME 560-ME Total weight [kg] 6,7 8,0 12,3 14,7 17,2 Adsorbents [kg] 1,0 1,6 2,4 3,5 4,8 Height [mm] Housing diameter [mm] Outside diameter [mm] Connection DIN DIN DIN A DIN B Valves [IN-OUT] GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 4/11

5 Part 5 Assembly and comissioning Proceed to assemble the entire adsorber as follows: 1. Turn off the system. 2. Mount connection part on the transformer to be ventilated. 3. Remove securing clips off the connection part. 4. Remove the securing plug off the adsorber part. 5. Plug the adsorber part to the connection part and close the tensioning clamps. 6. Secure the tensioning clamps with the securing clips. 7. Place the O-Ring inside the provided groove of the receiving part and check for correct seating. 8. Remove securing clips off the receiving part. 9. Remove the protective lamination on the bottom of the adsorber part. 10. Put the receiving part and the adsorber part together. 11. Hook the tensioning clamps into the locking hook and press the tensioning clamps down. 12. Secure the tensioning clamps with the securing clips. GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 5/11

6 Part 6 Maintenance Procedure for reusable adsorbers 1. Turn off the transformer. 2. Remove the receiving part by opening the tensioning clamps. 3. Remove the Adsorber by opening the tensioning clamps on the transformer. 4. Open the cover and remove it from the adsorber. 5. Remove the gasket inside the cover and replace it with new one. 6. Remove the dust filter disc. 7. Remove the active carbon disc and empty the desiccant. 8. Also remove the lower foam disc. 9. Install new foam disc. 10. 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. 11. Insert new active carbon disc. 12. Insert new dust filter disc and close the cover. 13. Put in new O-Ring between adsorber and connection part. 14. Afterwards plug the adsorber part into the connection part and close the tensioning clamps. 15. Secure the tensioning clamps with the securing clips. 16. Put in new O-Ring between adsorber part and receiving part. 17. Put the receiving part together with the adsorber part and close the tensioning clamps. 18. Secure the tensioning clamps with the securing clips. Procedure for disposable adsorbers 1. Turn off the transformer. 2. Remove the receiving part by opening the tensioning clamps. 3. Remove the Adsorber by opening the tensioning clamps on the transformer. 4. Plug in the new adsorber part to the connection part and close the tensioning clamps. 5. Secure the tensioning clamps with the securing clips. 6. Put in new O-Ring between adsorber part and receiving part. 7. Put the receiving part together with the adsorber part and close the tensioning clamps. 8. Secure the tensioning clamps with the securing clips. GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 6/11

7 Part 7 Spare parts and storage ADSORBER DUO-VARIO TB 300-PA DUO-VARIO TB 310-PA DUO-VARIO TB 320-PA DUO-VARIO TB 330-PA DUO-VARIO TB 500-PA DUO-VARIO TB 510-PA DISPOSABLE ADSORBER PART Adsorber part 301-PA Adsorber part 321-PA Adsorber part 501-PA REUSABLE SPARE PARTS KIT Spare parts kit 313-PA Spare parts kit 333-PA Spare parts kit 513-PA Adsorber part Build up - Adsorbents - Active carbon - Dust filter disc - Pre-assembled in the housing and air tight packed. DUO-VARIO TB 520-PA DUO-VARIO TB 530-PA DUO-VARIO TB 550-PA DUO-VARIO TB 560-PA DUO-VARIO TB 310-MA DUO-VARIO TB 330-MA DUO-VARIO TB 510-MA DUO-VARIO TB 530-MA Adsorber part 521-PA Adsorber part 551-PA Spare parts kit 533-PA Spare parts kit 563-PA Spare parts kit 313-MA Spare parts kit 333-MA Spare parts kit 513-MA Spare parts kit 533-MA Spare parts kit Content - Adsorbents - Active carbon filter discs - Dust filter disc - s Single and air tight packed. DUO-VARIO TB 560-MA Spare parts kit 563-MA DUO-VARIO TB 310-ME DUO-VARIO TB 330-ME DUO-VARIO TB 510-ME DUO-VARIO TB 530-ME Spare parts kit 313-ME Spare parts kit 333-ME Spare parts kit 513-ME Spare parts kit 533-ME Desiccant individually Content - Adsorbents Air tight packed. DUO-VARIO TB 560-ME Spare parts kit 563-ME 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 7/11

8 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 8/11

9 Part 9 Risk and hazard analysis 1 Overpressure resp. vacuum builds up inside the system 1.1 Valves 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 Dust filter disc contaminated The dust filter disc 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 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 Temperature range The ambient and operating temperatures should not exceed the specified range or below, otherwise the adsorber can be damaged. GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 9/11

10 3.4 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 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 dust filter disc regarding contamination Remove the cover from the adsorber part to remove the dust filter disc. Afterwards, the dust filter disc has to be checked for contamination and should be free from dirt for operating smoothly. The dust filter disc 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 receiving part has to be checked for their proper condition. For this, the gasket in the cover, the O-ring between connection part and adsorber part 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". Weekly Half-yearly Anually GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 10/11

11 4. Check valves for jamming The receiving part is visually checked for contamination and damage. To ensure the long-term functioning of the valves inside the receiving part they should be inspected. Remove the adsorber from the receiving part and check valves for functionality. If the valves won t open and close, the receiving part has to be replaced by a new one in order to ensure the full functioning. 5. 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. 6. 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 Weekly Two-yearly GIEBEL FilTec GmbH Web info@giebel-adsorber.de Tel +49 (0) Seite 11/11