Filters & Centrifugal Separators

Transcription

1 s & Centrifugal Separators Air flow rate 0.58 to 8 m 3 /min

2 Why use compressed air filters? On average, a compressor sucks in up to 90 million particles of dirt, hydrocarbons, viruses and bacteria with every cubic meter of atmospheric air. The compressor itself can only remove the larger dirt particles and the majority of the contaminants remain in the compressed air. This means that for most applications careful treatment of the air is necessary: Clean, quality compressed air maximises air-tool service life, ensures that pneumatic machinery and control systems operate at the peak of their performance and keeps pipes & valves free from contaminants. It therefore not only reduces service, maintenance and repair costs, but can also reduce initial investment costs. Compressed air filters Dependable and efficient Tailored compressed air treatment All Kaeser filters and compressed air treatment components are specifically designed for use in combination with one another. Compressed air of every quality class is available ranging from general works air right up to foodstuff and pharmaceutical grade air. compressed air filters are also available for high-pressure applications up to 6 bar (g). Centrifugal separator Sterile filters High-pressure filters Air filters Kaeser's extensive range of filters ensures that there's a model available to suit every compressed air need. Water, oil and dust are removed efficiently and with minimal differential pressure. Centrifugal separator For removal of liquid condensate. Typically used downstream from the compressor. Results in near 00 % relative humidity, which is ideal for further drying systems. s up to 8 or 6 bar We also have an extensive range of filters available for high-pressure applications, such as PET container production. Suited for use with pressures of up to 8 or 6 bar, these high-quality filters remove oil, water and dust. filters ensure a dependable and cost-effective source of quality compressed air Compressed air filters from KOMPRESSOREN are ideally suited for use with our compressors and compressed air drying systems. This ensures dependable compressed air treatment and exceptional efficiency Compressed air inlet Compressed air outlet housing element Electronically controlled ECO DRAIN condensate drain Air filters Certified: Clean compressed air Sterile filters These exceptionally reliable sterile filters are perfect for applications that require sterile, bacteriafree compressed air, such as those in the food and pharmaceuticals industries. Kaeser compressed air systems provide the required grade of compressed air quality to suit every compressed air application. This includes technically oil-free compressed air, which is many times cleaner than normal ambient air. All systems and equipment are tested and certified by the German Technical Inspection Institute (TÜV).

3 Compressed air filters Perfectly matched to compressor and compressed air treatment equipment, Kaeser s extensive range of filters ensures that all relevant compressed air quality classes are maintained reliably and efficiently over the long-term. Correct filtration for every compressed air need Use: For removal of solid particles and larger volumes of condensate. To be used as a pre-filter for solid particles and for removal of larger volumes of condensate. of particles removed: > 3 µm Max. fluid load at inlet: 5 g/m³ F pre-filter 3 µm Use: For removal of solid particles and small volumes of condensate. To be used as a pre-filter for solid particles and for removal of small volumes of condensate. A centrifugal separator or an air receiver should be installed upstream to provide initial removal of condensate. of particles removed: > µm Max. fluid load at inlet: g/m³ change maintenance indicator The filter monitor... (optional)... indicates when filter change is required. Microprocessor-controlled LCD display Comprehensive filter monitoring based on: - operating time - differential pressure - operation efficiency: comparison of increasing energy requirement caused by filter clogging to a maximum value that is dependent on the operating conditions and which is calculated by the monitor Significant energy savings change warning with red LED and alarm contact Continuous measurement of pressure differential to an accuracy of 0.05 bar via precision pressure transducer Direct data input, no separate programming device required FC pre-filter μm Use: For removal of solid particles To be used only as a dust filter for solid particles, often used downstream from desiccant dryers and activated carbon adsorbers. Through-flow from outside to inside ensures exceptionally high dust load capacity and maximum reliability. of particles removed: > µm Max. fluid load at inlet: Compressed air must be dry The high performance filter element... FD dust filter... ensures reliable filtration with minimal pressure losses: Coalescence filter with new, matrix filter-fibre structure High efficiency even at low air volumes of only five percent of nominal flow Reliable element-to-housing seal Stainless steel orifice tubes, oil & acid resistant coated sleeves and end caps Use: For removal of fine solid particles, condensate droplets and oil aerosols. For use as a fine filter for enhanced compressed air quality. The filter removes solid particles, condensate droplets and oil aerosols. of particles removed: > 0. µm Max. fluid load at inlet: g/m³ The filter housing that lasts: Long service life thanks to the epoxy resin coating inside and out (proven in over 000 hours of salt contamination tests) Easy filter element removal with Kaeser's O-ring seal system Minimal pressure drop due to optimised air flow The conical bowl and turbulence-free lower filter zone prevent condensate from being carried along with the air flow Audible warning should leakage occur The shut-off valve allows maintenance of the condensate drain without interrupting air supply Condensate drainage with the ECO Drain (optional) is electronically level-controlled and fully automatic, which means: No air losses Exceptional reliability FFG micro-filter combination comprises: FF micro-filter and FG activated carbon filter Available without electronic condensate drain FE fine micro-filter FF finest micro-filter FG activated carbon filter Use: For removal of solid particles, the smallest of condensate droplets and oil aerosols.the high capacity filter ensures exceptional compressed air quality in accordance with the most stringent requirements, e.g. for the pharmaceutical, electronics and foodstuff industries. Preferably use only with condensate-free compressed air. Ensure that a FE filter or a refrigeration dryer is installed upstream from this filter. of particles removed: > 0. µm Max. fluid load at inlet: 0. g/m³ Use: For removal of oil and adsorbable hydrocarbons, particularly suited to odour elimination. The activated carbon filter ensures exceptional compressed air quality in accordance with the most stringent requirements, e.g. for the pharmaceutical, electronics and foodstuff industries. Compressed air must be dried and filtered beforehand. Ensure that a FE/FF filter and a dryer are installed upstream from this filter. Designed for approx. 000 operating hours under reference conditions. Use an activated carbon adsorber (ACT series) if significantly longer service life is required. of particles removed: > 0. µm Max. fluid load at inlet: Compressed air must be dry Max. working pressure 6 bar Max. working temperature +66 C

4 Centrifugal separator Sterile filters Function: The centrifugal separator removes large volumes of condensate from the compressed air. Optimised design enhances the centrifugal effect and ensures a near constant degree of condensate separation over a wide flow volume range. Furthermore, particles up to 5 µm are also washed out. Application: A centrifugal separator is recommended for systems where the refrigeration dryer is installed directly downstream from the rotary screw compressor. The centrifugal separator is installed between the compressor and the refrigeration dryer and removes the liquid condensate from the compressed air. This provides the refrigeration dryer with additional reserve drying capacity. This is particularly important at high ambient temperatures in order to ensure that the required dew point is consistently maintained. centrifugal separators are maintenance-free. For sterile air: The FST sterile filter is made of high quality.30 (30) stainless steel that prevents bacterial growth and corrosion. The upper and lower housings are fitted with SP screw connections and plugs. All filter elements are subjected to multiple testing in the factory to ensure unrivalled reliability. All components comply with FDA regulations concerning contact with foodstuffs as per CFR (Code of Federal Regulations) Title. The pre-filter and micro-fibre web are made from of borosilicate. Retention of bacteria and particles occurs throughout the whole filter volume. On average, over 00 sterilisation cycles are possible with saturated steam (at C). Max. operating temperature range -0 to +00 C. Typical uses for FST sterile filters: Food and chemical industries Packaging industry Pharmaceuticals, medical technology, hospitals Tip: Each centrifugal separator should be fitted with an electronic ECO Drain condensate drain (available as a complete set with all necessary components). Tip: The use of a sterile filter requires appropriate sterilisation measures to be taken (e.g. in-line sterilisation or autoclave). These measures should be carried out at regular intervals. Centrifugal separator ZK06 to ZK0 Consistent degree of separation Water separation efficiency in % 00 centrifugal separator Electronically controlled condensate drain (recommended) Complete set with installation components FST sterile filter Degree of sterilisation in % sterile filters for bacteria-free compressed air % bacteria-free compressed air Flow capacity (% of nominal capacity) Flow capacity (% of nominal capacity)

5 s for 8 or 6 bar high-pressure 8/6 bar filters are available for installation at the booster outlet for special high-pressure applications, e.g. PET container production. These also ensure certified compressed air quality. 8/6 bar filters for every compressed air need Use: For removal of solid particles and larger volumes of condensate.to be used as a pre-filter for solid particles and for removal of larger volumes of condensate. of particles removed: > 3 µm Max. fluid load at inlet: 5 g/m³ housing Durable, pressure-resistant steel housing element Five different filter elements, ranging from pre-filters to activated carbon filters, are available for pressures up to 6 bar Special electronic condensate drain (optional) high-pressure filters can also be equipped with the electronically controlled ECO Drain condensate drain (PN 63). F filter FC filter Use: For removal of solid particles and small volumes of condensate. To be used as a pre-filter for solid particles and for removal of small volumes of condensate. A centrifugal separator or an air receiver should be installed upstream to provide initial removal of condensate. of particles removed: > µm Max. fluid load at inlet: g/m³ Use: For removal of fine solid articles, condensate droplets and oil aerosols. For use as a fine filter for enhanced compressed air quality. For removal of solid particles, condensate droplets and oil aerosols. of particles removed:> 0. μm Max. fluid load at inlet: g/m³ FE filter Use: For removal of solid particles, the smallest of condensate droplets and oil aerosols.the high capacity filter ensures exceptional compressed air quality in accordance with the most stringent requirements, e.g. for the pharmaceutical, electronics and foodstuff industries. Preferably use only with condensate-free compressed air. Ensure that an FE filter or a refrigeration dryer is installed upstream from this filter. of particles removed: > 0. µm Max. fluid load at inlet: 0. g/m³ FF filter Compressed air system with booster Schematic illustration Low pressure network up to 3 bar Air tools Rotary screw compressor Air receiver ooster Pre-filter High pressure air receiver High pressure refrigeration dryer High pressure micro-filter Compressed air network at 5 bar FG filter Max. working pressure 8 or 6 bar Use: For removal of oil and adsorbable hydrocarbons, particularly suited to odour elimination. The activated carbon filter ensures exceptional compressed air quality in accordance with the most stringent requirements, e.g. for the pharmaceutical, electronics and food / beverage industries. Use only with compressed air that has already been dried and filtered. Ensure that a FE/FF filter and a dryer are installed upstream from this filter. Designed for approx. 000 operating hours under reference conditions. Use an activated carbon adsorber (ACT series) if significantly longer service life is required. of particles removed: > 0. µm Max. fluid load at inlet: Compressed air must be dry

6 Technical specifications series: F, FC, FD, FE, FF, FG, FFG s: 6, 0, 8, 8, 8, 7, 07, 38, 77,, 85, 83, 35, 56, 708, 885, 0, 950, 80 Versions: Normal with float-controlled drain D With electronic level-sensing controlled ECO DRAIN condensate drain Aluminium casing for filter s from 6 to, Steel casing for filter s from 85 to 80 Designation: housing series Version FE D Series E-E- Compressed air filter for max. 6 bar, max. operating temp. +66 C Replacement filter element A Flow rate *) m³/min F FFG Air connection F FFG Weight kg (Standard version) Dimensions A,, C in mm (Standard version) F FC FD FE FF FG FFG F FC FD FE FF FG FFG (for maintenance) mm No. F FC FD FE FF FG R 3/ , 33, 63 05, 306, 05, 306, 05, 8, 63 0, 306, 76 6 E--6 E-C-6 E-D-6 E-E-6 E-F-6 E-G R / , 306, 05, 306, 05, 306, 05, 55, 0, 306, 76 0 E--0 E-C-0 E-D-0 E-E-0 E-F-0 E-G R / , 367, 85 05, 367, 85 05, 367, 85 05, 36, 85 0, 367, E--8 E-C-8 E-D-8 E-E-8 E-F-8 E-G R 3/ , 389, 98 33, 389, 98 33, 389, 98 33, 338, 98 66, 389, E--8 E-C-8 E-D-8 E-E-8 E-F-8 E-G R , 97, 06 33, 97, 06 33, 97, 06 33, 6, 06 66, 97, E--8 E-C-8 E-D-8 E-E-8 E-F-8 E-G R / , 579, 8 6, 579, 8 6, 579, 8 6, 58, 8 38, 579, E--8 E-C-7 E-D-7 E-E-7 E-F-7 E-G R / , 693, 596 6, 693, 596 6, 693, 596 6, 6, , 693, E--07 E-C-07 E-D-07 E-E-07 E-F-07 E-G-07 C R , 789, 68 9, 789, 68 9, 789, 68 9, 739, , 789, E--38 E-C-38 E-D-38 E-E-38 E-F-38 E-G R / , 935, 87 9, 935, 87 9, 935, 87 9, 885, , 935, E--77 E-C-77 E-D-77 E-E-77 E-F-77 E-G-77. R / , 09, 983 9, 09, 983 9, 09, 983 9, 00, , 09, E--38 E-C- E-D- E-E- E-F- E-G- A DN , 30, , 05, , 30, , 05, , 30, E--85 E-C-85 E-D-85 E-E-85 E-F-85 E-G DN , 05, 03 00, 05, , 05, 03 00, 05, , 05, E--83 E-C-83 E-D-83 E-E-83 E-F-83 E-G DN , 0, 03 00, 05, , 05, 03 00, 05, , 05, E--85 E-C-85 E-D-85 E-E-85 E-F-85 E-G DN , 0, 03 0, 085, 868 0, 0, 03 0, 085, , 0, E--85 E-C-85 E-D-85 E-E-85 E-F-85 E-G DN , 55, 0 535, 05, , 55, 0 535, 05, , 55, E--85 E-C-85 E-D-85 E-E-85 E-F-85 E-G-85 C DN , 55, 0 535, 05, , 55, 0 535, 05, , 55, E--85 E-C-85 E-D-85 E-E-85 E-F-85 E-G-85 0 DN , 355, , 5, , 355, , 5, , 355, E--85 E-C-85 E-D-85 E-E-85 E-F-85 E-G DN , 50, 83 70, 5, , 50, 83 70, 5, 908 0, 50, E--85 E-C-85 E-D-85 E-E-85 E-F-85 E-G DN , 50, 9 750, 65, , 50, 9 750, 65, , 50, E--85 E-C-85 E-D-85 E-E-85 E-F-85 E-G-85 Correction factors Working pressure bar Conversion factor for flow rate A Designation: High-pressure filters series High Pressure series High Pressure s for 8 or 6 bar Flow rate *) m³/min Air connection Weight kg Dimensions A, mm Removal height F FC FE FF FG F FC FE FF FG mm.75 8 R / 9 37 x R 9 37 x R 59 x DN x Correction factors F 8 HP 6 Max. pressure Max. working pressure bar Replacement filter elements No. E-E-8/8 HP 6 Replacement filter element for high-pressure filter series F FC FD FE FF 8 E--8/8 E--8/8 E--8/8 E--8/8 E--8/8 8 E--8/8 E--8/8 E--8/8 E--8/8 E--8/8 7 E--7 E-C-7 E-E-7 E-F-7 E-G-7 E--83 E-C-83 E-E-83 E-F-83 E-G-83 Max. pressure Working pressure bar Conversion factor for flow rate *) Air flow at 7 bar (g) referred to bar (a) and 0 C

7 Technical specifications Designation: Sterile filters Sterile filters F 6 P-ST s Sterile Replacement filter elements 03/0 P-ST Sterile Flow rate *) m³/min Compressed air connection Weight kg Dimensions A,, C mm (for maintenance) (upwards) mm No. Replacement filter element for sterile filter 6 R /.7 5; 08; R 3/8.9 5; 08; 55 0 R /.9 5; 08; R 3/ 70; 5; R.6 300; 5; R / 3 350; 0; R /.3 380; 70; R.8 55; 70; R ; 70; 9 50 R / 9 765; 6; R ; 6; R ; 0; /0 P-ST 9 0/0 P-ST 0/0 P-ST 8 05/0 P-ST 7 05/5 P-ST 36 07/5 P-ST 8 07/30 P-ST 7 0/30 P-ST 08 5/30 P-ST 0/30 P-ST 9 30/30 P-ST 88 30/50 P-ST A C Correction factors Working pressure bar Conversion factor for flow rate Sterile filter Centrifugal separator for max. 6 bar Flow rate *) m³/min 7 bar 0 bar Model Compressed air connection Volume l Weight kg Dimensions H x W x Ø mm.0.3 ZK 0 G 3/ x 89 x. 5.0 ZK 0 G x 09 x ZK 03 G / x 09 x ZK 0 G / x 09 x ZK 05 G x 50 x ZK 06 DN x 370 x ZK 07 DN x 00 x ZK 07 DN x 00 x ZK 08 DN x 50 x ZK 08 DN x 60 x ZK 09 DN x 550 x ZK 09 DN x 550 x ZK 0 DN x 570 x 3 *) Air flow at 7 bar (g) referred to bar (a) and 0 C H Centrifugal separator ZK 0 to ZK 05 H Ø Centrifugal separator

8 filters Options and accessories The filter monitor Indicates when filter change is required. Indicates filter changes based on prescribed operational parameters Continuous measurement using intelligent electronics Easy-to-read LCD display, alarm LED Digital display of pressure drop Condensate drain ECO DRAIN Non-wearing electronic sensor, no moving parts Maximum reliability, no sticking or clogging No compressed air losses Test button Self-monitoring electronics with automatic alarm sequences Volt-free alarm contact LEDs for power supply and alarm AC and DC versions (50 / 60 Hz) available All controls are water-resistant as per IP 65 monitor box The Monitor ox allows remote filter monitoring. It evaluates the signals from a filter monitor, as well as from an ECO Drain condensate drain, and can pass messages to acentral maintenance control system via two alarm contacts. Group alarm(volt-free contact) Indication of (time-controlled) service interval for filter element change Indication of optimum time for filter element change computed via measurement value processing Maximum differential pressure exceeded ( minute delay) Condensate drain alarm Safety alarm (volt-free contact only active inactive safety mode) Maximum differential pressure exceeded (5 second delay) The power supply for the filter monitor and ECO-Drain is provided by the monitor box. Wall racket Simple installation: Remove differential pressure indicator, remove fixing screws Screw the bracket to the wall Screw the filter housing to the bracket Re-install the differentialpressure indicator Modular design The specially designed housing allows various filters to be combined together in series without the need for additional piping. Certified Compressed Air Quality The oil and solid particle content is reliably kept below ISO Class limits. After passing through the air treatment systems, the delivered compressed air is designated as technically oil-free. The quality of the air produced by the compressed air system is tested and certified by TÜV, the German Technical Inspection Authority. Note: Please also consider Air Main Charging Systems (See brochure P773), as these also help to ensure consistent compressed air quality. Genuine replacement filter elements Only genuine replacement filter elements ensure reliable filtration with minimal pressure losses. Coalescence filter with new, matrix filter-fibre structure High efficiency even at low air volumes of only five percent of nominal flow Reliable element to housing seal Element supported by oil and acid resistant stainless steel orifice tubes and end caps replacement filter elements are also available for other housings. Timely filter changes significantly reduce energy costs Annual energy costs in Euros Operational parameters: 6000 operating hours/year /kwh - bar = 8 % more energy Example: With a 75 kw compressed air system, approx. 00 /year can be saved Pressure drop in bar 0 kw 75 kw 5 kw 30 kw kw kw Compressor power Comprehensive design know-how KESS ( s Energy Saving System) provides comprehensive analysis of your compressed air usage, enabling s experts to plan and design a system that is specially tailored to meet all of your compressed air needs. Typically ensuring a % load capacity, compressed air systems provide exceptional efficiency and produce application-specific quality compressed air at lowest possible cost. Use this expertise to your advantage and let design your compressed air system. Reduce operating costs A pressure loss of only approx bar is significantly more expensive than the costs required to change the filter element. Timely filter changes save considerable operating costs. Investment costs element costs Operating time Pressure element loss costs 0.7 bar = 00 % 0.6 bar = 70 % 0.5 bar = 5 % 0. bar = 5 % 0.35 bar = 00 % 0.3 bar = 85 % 0. bar = 60 % 0. bar = 5 %

9 Choose the required grade of treatment according to your field of application: Air treatment using a refrigeration dryer (+3 C pressure dew point) Examples: Selection of treatment classes to ISO ) Pure air and cleanroom technology Dairies, breweries Food and semi-luxury food production Very clean conveying air, chemical plants Pure air and cleanroom technology Pharmaceutical industry Weaving machines, photo labs Paint spraying, powder coating Packaging, control and instrument air General works air, high-grade sand blasting Shot blasting 7 3 Low-grade shot blasting F 3 7 For rotary screw compressors Conveying air for waste water systems 3 9 No quality requirements Other machines For air mains subject to sub-zero temperatures: Compressed air treatment with a desiccant dryer (down to -70 C pressure dew point) Pharmaceutical industry, dairies, breweries Microchip production, optics, food and semi-luxury food production Paint spraying Pure air and cleanroom technology Process air, pharmaceuticals Photo labs Especially dry conveying air, paint spraying, fine pressure controllers Solids Water Oil acteria 3 Solids Water Oil acteria Pure air and cleanroom technology FST FE FST FST FST FE FG FD FD FFG ACT FE ACT FD * * FF FF * * FC RD ED Compressor THNF DD FE ED Installation for heavily fluctuating air demand Aquamat *in refrigeration dryer, FE microfilters are optional for TG to TI series dryers. s Air receiver DD FE ZK s Air receiver RD ZK Installation for heavily fluctuating air demand Compressor THNF Aquamat Explanation: THNF = ag filter Cleans dusty and heavily contaminated intake air ZK = Centrifugal separator Separates accumulating condensate ED = Eco Drain Electronic level-controlled condensate drain F = Pre-filter FC = Pre-filter FD = Particulate filter (attrition) FE = Micro-filter Separates aerosol oil and solid particles FF = Micro-filter Separates aerosol oil and solid particles FG = Activated carbon filter For adsorption of oil vapours FFG = Activated carbon and micro-filter combination RD = Refrigeration dryer For drying compressed air, pressure dew point to +3 C DD = Desiccant dryer For drying compressed air, pressure dew point to -70 C ACT = Activated carbon adsorber For adsorption of oil vapours FST = Sterile filter For sterile compressed air Aquamat = Condensate treatment system = Air-main charging system Contaminants: + Solids + Water/Condensate + Oil + acteria Degree of filtration: Class ISO Solid particles ) Humidity ) Max. particle µm Max. particle Pressure concentration (x = liquid water dew point mg/m³ in g/m³) 0 e.g. Consult Kaeser regarding pure air and cleanroom technology Total oil content ) mg/m³ x < x < x 0 ) As per ISO 8573-:99 (The specification for particle content is not measured as per ISO 8573-:00, as the limits defined there in for Class are to be applied to Clean Rooms ) ) As per ISO 8573-:00 KOMPRESSOREN GmbH P.O. ox Coburg GERMANY Tel: Fax: productinfo@kaeser.com P-75ED.7/08 Specifications are subject to change without notice