FST FCA/50 Series, FCA20/50, FCA25/50, FCA30/50, FCA50/50 Operating Manual

Operating Manual

Filter for Compressed Air
Series FCA/50 Version: 10/2013/EN

Water Separator............................... FCA 30 - 130

Coalescing Filter............................... FCA 20 - 130

Activated Carbon Filter.................. FCA 20 - 130

Dust Filter......................................... FCA 20 - 130

©

FST GmbH

14.06.2018

DMN FST manual FCA20

-

130_50 W

-

A Standard

-EN-

20131014

-

CR.docx

Table of contents

1. General information ........................................................................................................................................ 4

1.1 Manufacturer........................................................................................................................................... 4

1.2 Definitions ............................................................................................................................................... 4

1.3 Warranty notes ........................................................................................................................................ 5

1.4 About this operating manual ................................................................................................................... 5

2. Description of application ............................................................................................................................... 7

2.1 Intended use ............................................................................................................................................ 7

2.2 Technical data .......................................................................................................................................... 8

3. Safety notes ................................................................................................................................................... 10

3.1 Signs and instructions ............................................................................................................................ 10

3.2 Danger zones at the filter ...................................................................................................................... 11

3.3 General safety notes .............................................................................................................................. 13

4. Technical product description ....................................................................................................................... 14

4.1 Function description .............................................................................................................................. 15

4.2 Options .................................................................................................................................................. 16

5. Transportation and storage ........................................................................................................................... 17

5.1 Transportation ....................................................................................................................................... 17

5.2 Storage ................................................................................................................................................... 17

6. Installation ..................................................................................................................................................... 18

6.1 Installing the connecting pipelines ........................................................................................................ 18

7. Commissioning .............................................................................................................................................. 20

7.1 Pressurisation of the filter ..................................................................................................................... 20

8. Decommissioning .......................................................................................................................................... 21

9. Maintenance and repair ................................................................................................................................ 22

9.1 Regular maintenance intervals .............................................................................................................. 23

9.1.1 Condensate drain (if available): visual check and function monitoring ........................................ 24

9.1.2 Differential pressure gauge (if available): visual check and function monitoring ......................... 24

9.1.3 Replacing the filter element .......................................................................................................... 24

10. Errors and measures ...................................................................................................................................... 27

11. Appendix and technical documents .............................................................................................................. 28

11.1 General arrangement drawing and filter configuration ........................................................................ 28

General information

1. General information

1.1 Manufacturer

FST GmbH

Head office: Weiherdamm 17 – 57250 Netphen, Germany

Sales office: Im Teelbruch 106 – 45219 Essen, Germany

 [phone]

 [phone]

 [e-mail]

! For any questions about the product, please contact the sales office !

In case of questions about the product, please specify the following:

 Filter type: e.g. FCA 70/50 XNM
 Filter element type: e.g. EFST70XN
 Manufacturing number: e.g. 10/12/24

This information can be found on the type plate of the filter housing. (→ Page 10)

1.2 Definitions

In the following the term „filter“ will be used as a common substitute for the terms „water separator“, „coa­lescing filter“, „activated charcoal filter“ and “dust filter” as far as common properties are concerned.

4

General information

1.3 Warranty notes

For warranty information, please refer to our "General Terms of Sale and Delivery".
(→ www.fstweb.de)

In the following cases the warranty shall be void:

 If the safety notes and instructions of this operating manual and of the additional documents are not

observed.

 If the filter is operated or maintained by personnel who do not have the required qualifications. (→

see "Target group": page 5)

 If the filter is used for anything other than its intended use. (→ Page 7)
 If aggressive substances in the compressed air or ambient air cause damage to the filter.
 If parts other than genuine parts of the manufacturer have been used for maintenance and repair.
 If the filter is operated although defects are evident.

1.4 About this operating manual

This operating manual contains all the technical information required for installation, operation, maintenance
and disposal of the filter.

Target group

This operating manual is directed to all persons working on and with the filter. We point out that these per­sons have to be qualified personnel who, because auf their qualification and experience, are familiar with han­dling pressure equipment and compressed air systems. If you are not experienced in using these systems,
please ask the relevant experts for help. We recommend that installation, commissioning and maintenance be
carried out by a compressed air specialist company.

Using the operating manual

Please read the operating manual and the additional documents carefully prior to installation and follow the
notes and instructions. Safe and proper operation of the filter can only be guaranteed if the instructions and
notes are observed. The safety notes must be observed in particular.

The operating manual must be kept in the vicinity of the filter and must be easily accessible.

When selling or hiring out the filter, also provide this operating manual and all the additional documents to the
new user.

The manufacturer accepts no liability for damages resulting from disregard of the operating manual.

All the information in this operating manual is valid at the time the manual is published. Due to component or
workflow modifications at any time affecting filter maintenance, the latest information should be available
prior to maintenance work.

5

General information

CAUTION !

WARNING !

DANGER !

Note!

Tips and hints!

Signs and symbols used

 Boxes are used for bulleted lists.

1) Enumerated lists point out that the working steps are to be carried out in a specified order.

→ Cross references refer to information on a different page or in a different document.

This symbol refers to matters that should be given special attention.
Observing the notes helps to ensure safe handling of the product.

This symbol refers to matters that should be given special attention.
Observing the advisory notes helps to ensure particular efficient operation of the product.

This symbol indicates a possible harmful situation.
When not avoiding this situation, there is a danger of injury to persons or damage to the product
or to adjacent system components.

This symbol indicates a possible dangerous situation.
When not avoiding this situation, there is a danger of serious injury or death.

This symbol indicates an immediate impending danger.
Not avoiding this danger results in serious injury or death.

6

Description of application

DANGER !

Caused by fire and explosion when used for oxygen

2. Description of application

The filter is used to remove solid, liquid and – for activated carbon inserts – also gaseous contaminants from
the compressed air, nitrogen and other uncritical fluid group 2 gases (group 2 fluids: → see Pressure Equip­ment Directive 97/23/EC).

Typically, the filter is used for treating compressed air from a compressor station. The filter almost completely
removes dust, oil droplets and condensate from the compressed air. The filter version with an activated car­bon filter element also removes oil vapour from the compressed air until the residual oil content is negligible.

The specifications on filter performance in this operating manual and in the product data sheets exclusively
refer to compressed air and nitrogen. For specifications with regard to other gases please contact the manu­facturer or one of the authorised service partners.

2.1 Intended use

The filter is exclusively designed for cleaning compressed air and nitrogen!
Using the filter for cleaning other gases (e.g. carbon dioxide) must be agreed on with the manufacturer. It may
be necessary to observe special safety directives.

When oxygen comes into contact with grease in the filter and accessories there is a danger of vio­lent fire and filter bursting.
Never use this filter for oxygen or gases rich in oxygen.
For filtration of oxygen please ask the manufacturer for advice.

The filter is designed to be set up at a site that complies with the following requirements:

 Frost-free
 Dry
 No vibration via brackets or connected piping
 Free from dangers due to explosive atmospheres inside and outside the filter. (The standard filter

version does not comply with ATEX.)

The filter must only be operated with compressed air or nitrogen within the maximum allowable operating
conditions.
The maximum allowable operating conditions are defined on the type plate (→ page 10).

Modifications to the filter or use of non-genuine parts may cause unpredictable danger and damage. These
measures must only be carried out after previous inspection and approval of the manufacturer. Only use genu­ine spare parts of the manufacturer.
Any other use is considered improper and therefore not permissible. The manufacturer accepts no liability
caused by improper use.
For the nominal operating conditions please refer to the following table. (→ Page 8)
For a filter designed to your individual operating conditions and for other gases, please refer to your contract
documents or contact the manufacturer.
Filtration performance may be reduced considerably if the filter is not operated within these operating condi­tions.

7

Description of application

All filter versions

The filter might be damaged by aggressive and corrosive contami-

The filter only removes finely distributed contaminants (aerosols)

The filter only removes gaseous contaminants (vapour) carried in the

A

dust filter

with a flow

direction

from outside to inside of the filter

Compressed air

The supplied compressed air must comply with the following requirements:

Free from aggressive
and corrosive substances

Coalescing filters
Free from bulk water,
coarsely filtered

Activated carbon filters

free of liquid contaminants,
Finely filtered

Dust filters

free of liquid contaminants

2.2 Technical data

nants. Such damages might result in dangerous situations.

carried in the compressed air. Flowing liquids may lead to overload­ing of the filter. The filter must be protected against water shocks
and splashing water. We highly recommend coarse filtration using a
water separator upstream of the coalescing filter.

compressed air. Liquids contaminants may lead to overloading of the
filter. The filter must be protected against liquid contaminants. We
highly recommend fine filtration using a coalescing filter upstream of
the activated carbon filter.

element can only remove solid contaminants.
This filter shall be protected against liquid contaminants. We highly
recommend fine filtration using a coalescing filter and drying up­stream of the dust filter.

Water Separator

Filter

V [m³/h]* Zoll [kg] [mm] [mm] [mm]

FCA30/50 255 G 3/8 1,1 215 87 80 EFST30W**
FCA50/50 357 G 1/2 1,1 215 87 80 EFST30W**
FCA70/50 510 G 1/2 1,1 215 87 80 EFST30W**
FCA90/50 816 G 3/4 4,0 321 130 122 EFST90W**
FCA95/50 816 G 1 4,0 321 130 122 EFST90W**
FCA110/50 1,683 G 1 4,0 321 130 122 EFST90W**
FCA115/50 1,683 G 1 ½ 4,0 321 130 122 EFST90W**
FCA120/50 2,550 G 1 ½ 4,0 321 130 122 EFST120W**
FCA130/50 4,080 G 1 ½ 4,0 321 130 122 EFST120W**

rate

Nominal

volume flow

connection

Weight

Height

Width

Depth

Matching

filter insert

8

Description of application

0.6 169 61 60

0.6 169 61 60

1.1 215 87 80

1.1 215 87 80

1.3 285 87 80

4.0 321 130 122

4.0 321 130 122

4.5 421 130 122

4.5 421 130 122

5.0 521 130 122

6.5 721 130 122

Classification acc. to PED 97/23/EC



FCA20/50 to FCA70/50:

Article 3 (3)

Fluid group

2

Max. allowable pressure (PS)

50 bar

Min. pressure

Filter housing :

- 1bar g (i.e. negative pressure)

Max. allowable temperature (TS)



Filter housing without filter element:

120°C

Min. allowable temperature (TS)

+1°C

Coalescing Filter, Dust Filter and Activated Charcoal Filter

Filter

FCA20/50 153 G 1/4
FCA25/50 179 G 3/8
FCA30/50 255 G 3/8
FCA50/50 357 G 1/2
FCA70/50 510 G 1/2
FCA90/50 816 G 3/4
FCA95/50 816 G 1
FCA110/50 1,683 G 1
FCA115/50 1,683 G 1 ½
FCA120/50 2,550 G 1 ½
FCA130/50 4,080 G 1 ½

Nominal

V [m³/h]*

volume flow rate

Compressed air

Inch [kg] [mm] [mm] [mm]

All Filters

connection

Weight

Height

Width

Depth

Matching

filter element

EFST25**
EFST25**
EFST30**
EFST50**
EFST70**
EFST90**

EFST90**
EFST110**
EFST110**
EFST120**
EFST130**

 FCA90/50 to FCA120/50: Category I
 FCA130/50: Category II

Attention! Condensate drains require a minimum positive pressure
to operate. (app. 1…2bar g) The required min. positive pressure
can be found in the datasheets of the condensate drains.

 Filter with filter element V, ZN, XN, XXN: 65°C
 Filter water separator W: 65°C
 Filter with filter element A : 45°C

* = Standardised to 1 bar(a) and 20°C as well as to operating conditions of 50 bar operating overpressure.

** = The filter can be used with filter elements providing different filtration performances. The letter at the

end of the filter element name specifies the filtration performance. For detailed information on the fil­tration performance of the different elements and for other details, please refer to the relevant prod­uct data sheet. The product data sheets can be found on the Internet at:

→ www.fstweb.de → Download

9

Safety notes

Note!

Type plate of the filter

3. Safety notes

The filter has been built according to state-of-the-art technology and recognised safety rules. However, there
is a risk of danger that every person working with the filter must be aware of. In particular, improper handling
of compressed air may result in serious injury or death. If you are not experienced in using pressure equip­ment, please ask the relevant experts for help.

 In order to prevent personal injury or damage to the equipment, the safety notes must be

observed when using this filter.

 Observe the specific safety notes in the relevant chapters.
 Observe the legal guidelines and the accident prevention regulations.
 Observe the safety notes of the local site regulations.

3.1 Signs and instructions

on the filter housing

(example: FCA70XNM)

The type plates show important information. Make sure that the type plates are always clearly readable.

10

Filter housing

Possible

accessories

Possible

accessories

3.2 Danger zones at the filter

3

1

1

2

1

1

1

1 Danger from pressure-bearing parts
2 Danger from hot surfaces
3 Danger from electric voltage

1

Safety notes

on upper filter part

on lower filter part

1

11

Safety notes

DANGER !

– Overpressure (1)

WARNING !

– Hot surfaces (

2)

DANGER !

–

Electric voltage (

3)

The filter is pressurised.
Suddenly escaping compressed air may result in serious injury.
Do not carry out mechanical work on the filter as long as the filter is pressurised.

Depending on the temperature of the compressed air the filter surfaces may be very hot.
Unprotected touching of these surfaces may cause burns.
Avoid direct contact to these surfaces. Restrict access to the surfaces, if necessary, or install ther­mal insulation on the hot components.
Never exceed the maximum allowable temperature of the filter. (→ Page 8).

The accessories on the filter may be operated with electric voltage.
Touching live parts may result in serious injury or death.
Work on electrical components must only be carried out by qualified and authorised personnel.
Use a voltage detector to make sure the accessories have been disconnected from the power sup­ply and that there are no live parts in and on the filter before starting maintenance work.
In the event of fire, do not extinguish the fire using water.
Observe the specific operating manuals for electrical accessories and the safety notes included.

12

DANGER !

– Overload

DANGER !

– Unauthorised modifications

DANGER !

– Suspected misuse

Additional safety notes

3.3 General safety notes

The filter must only be operated with compressed air within the maximum allowable operating
conditions. The operating conditions are defined on the type plate (→ page 10).
Exceeding the maximum allowable operating conditions may result in serious injury or death.
It is the duty of the operator to ensure that the connected pressure source is safeguarded such
that the maximum allowable operating pressure (PS) and the minimum and maximum allowable
temperatures (TS) are not exceeded.
Please also refer to section "Intended use". (→ Page 7)

Modifications to the filter may result in dangerous operating states. Violations may cause serious
injury or death.
Never modify the filter function by means of conversions.
Never carry out welding work on pressure-bearing parts.
Any modifications of the filter must be agreed on with the manufacturer and confirmed in writing.

Safety notes

Using the filter for unintended purposes may result in dangerous situations. Violations may cause
serious injury or death.
Never use the filter as a climbing aid.
Never use the filter as a support for external weight loads.
Never use filter components for unintended application purposes.
Please also refer to section "Intended use". (→ Page 7)

Additional safety notes can be found in the relevant chapters and operating manuals for the dif­ferent accessories.

13

Technical product description

Upper filter part with compressed air inlet and

7 Condensate drain: manual drain

outlet (one o

-

ring for sealing the filter housing

8 ---

parts is inside the upper filter

part)

9 Shut-off valve

2 Filter bowl

---

3 Filter element or filter cartridge (inside)

Condensate drain: electronic (external)

4 Plug screw

5 Differential pressure gauge (option)

6 ---

G 1/2“i

G 1/2“i

Filter housing

Possible

accessories

Possible

accessories

4. Technical product description

4

5

1

2

on upper filter part

1

11

9

G 1/4“i

3

7

on lower filter part

7

For further filter views and filter combinations, please refer to the appendix.

14

10
11

Technical product description

Special disposal of the condensate

4.1 Function description

Water Separator (type W)

The filter (1) is installed in the compressed air piping. The compressed air is flowing through the filter. In the
filter the compressed air is led onto the separator insert (3). The separator insert comprises guide vanes that
divert the air flow into a tornado-like vortex. Droplets are centrifuged out of the air low onto the walls of the
filter housing. Thus the droplets are separated from the air flow.
Gravity draws the liquids down. The droplets are collected in the filter bowl (2) until a small amount of liquid
has been produced (condensate). This liquid is discharged from the filter using a condensate drain (7 to 11).

When using a water separator the air flow direction through the filter always is from the outside to the inside.

Coalescing Filter and Dust Filter (Type V, ZN, XN, XXN)

The filter (1) is installed in the compressed air piping. The compressed air is flowing through the filter. In the
filter the compressed air is led through a filter element (3). The filter element comprises a filter fleece in the
form of a dense fabric consisting of finest fibres.
The compressed air freely flows through the filter fleece. Dust particles and finest droplets, however, are
trapped in the fibre fabric and separated from the compressed air flow in this way.
The dust particles remain in the filter fleece.
The droplets pass the filter fleece and merge with one another to form larger droplets (coalescence effect).
These larger droplets leave the filter fleece on the outside of the filter element and are drawn down by gravity
to finally drop of the filter element.
The droplets are collected in the filter bowl (2) until a small amount of liquid has been produced (condensate).
This liquid is discharged from the filter using a condensate drain (7 to 11).

When using a coalescing filter the air flow direction through the filter element always is from the inside to the
outside.
When using dust filter the air flow direction through the filter element normally is from the outside to the
inside. If the air flow through the filter element is to be in the opposite direction, the correct polarity of the
differential pressure gauge must be observed. Changing the direction of flow also requires the polarity of the
differential pressure gauge to be changed. The -connection of the differential pressure gauge shall be con­nected to the inlet side of the filter.

Usually, the condensate from compressed air filters is contaminated and consists of an oil/water
mixture. This kind of condensate must not be discharged into the municipal wastewater system.
The filter manufacturer also offers condensate treatment systems which clean the condensate and
treat it such that it can be disposed off into the municipal wastewater system.

15

Technical product description

Activated Carbon Filter (Typ A)

The filter (1) is installed in the compressed air piping. The compressed air is flowing through the filter. In the
filter the compressed air is led through an activated carbon element (3). The activated carbon in the activated
carbon element removes the oil vapour from the compressed air and stores it in its internal structure.
The activated carbon element (3) is fitted with a filter fleece in the form of a dense fabric consisting of finest
fibres.

The compressed air freely flows through the filter fleece. Dust and carbon particles, however, are trapped in
the fibre fabric and separated from the compressed air flow in this way.
The dust and carbon particles remain in the filter fleece.

When using an activated carbon filter the air flow direction through ...

 the activated carbon element always is from the inside to the outside.

Continuous loading of the activated carbon with contaminants results in reduced cleaning performance until
the activated carbon finally is saturated. The saturated activated carbon element needs to be replaced by a
new activated carbon element, respectively. The service life of the activated carbon element depends on the
quality of the inflowing compressed air. (→ Page23)

4.2 Options

The filter can be configured individually.

 Different differential pressure gauges (from FCA30/50 and higher)
 condensate drains
 Several filters can be installed to form filter combinations.
 Wall mounting kits are available for filters up to filter size FCA 130/50 (for single filters only).

For possible configurations, please refer to the appendix or the manufacturer's price list.

For a detailed description of the options, please refer to operating manuals and product data sheets provided
separately.

The product data sheets can be found on the Internet at: → www.fstweb.de → Download

16

Transportation and storage

DANGER !

– Damage

5. Transportation and storage

5.1 Transportation

Damages on the filter may lead to unpredictable hazardous situations.
Operating a damaged filter may result in serious injury or death.
Never start or operate a damaged filter.

Although great care is taken damages caused by transportation cannot be ruled out. Therefore, always check
the filter for possible damages after transportation and packaging removal.
The haulage contractor and the manufacturer or the sales partner must immediately be informed about any
damage.

 Consider the size and weight of the filter. (→ Page 8)

The use of auxiliary equipment might be necessary for carrying/transporting the filter. Make sure to
provide adequate lifting equipment when transporting and loading or unloading the filter.

 Persons responsible for transportation must be appropriately qualified.
 Do not remove the packaging material until the filter is moved to its final place of installation.
 The national regulations for accident prevention must be adhered to.

5.2 Storage

To maintain the filter quality the filter must be stored at a suitable location and properly prepared for storage.

Store the filter in the supplied transport packaging. If necessary, the filter should be protected against dust
using an additional cover.

The place of storage has to fulfil the following requirements:

 Indoors
 Protected against weather impact
 Frost-free
 Dry

17

Installation

DANGER !

– Overload

DANGER !

– Bursting components due to external forces

DANGER !

– Electric voltage

DANGER !

– Overpressure

6. Installation

6.1 Installing the connecting pipelines

The filter is under pressure.
Suddenly escaping compressed air may result in serious injury.
Do not carry out mechanical work on the filter as long as the filter is under pressure.

The filter must only be operated with compressed air within the maximum allowable operating
conditions. The operating conditions are defined on the type plate (→ page 10).
Exceeding the maximum allowable operating conditions may result in serious injury or death.
It is the duty of the operator to ensure that the connected pressure source is safeguarded such
that the maximum allowable operating pressure (PS) and the minimum and maximum allowable
temperatures (TS) are not exceeded.
Please also refer to section "Intended use" (→ page 7).

The filter components are not designed for externally applied forces and may burst due to addi­tional load impact.
Bursting, pressure-bearing components may result in serious injury or death.
The support required for the connected pipelines has to be provided by the customer. Transmis­sion of loads or stress into the connection points of the filter is not permissible.

Proper installation is required for safe and error-free operation of the filter.

To avoid damages during transportation the accessories may be provided separately and need to be mounted
to the filter after the filter has been installed at the place of installation.

Please observe the following steps when installing the compressed air pipeline:

The accessories on the filter may be operated with electric voltage.
Touching live parts may result in serious injury or death.
Work on electrical components must only be carried out by qualified and authorised personnel.
Use a voltage detector to make sure the accessories have been disconnected from the power sup­ply and that there are no live parts in and on the filter before starting maintenance work.
In the event of fire, do not extinguish the fire using water.
Observe the specific operating manuals for electrical accessories and the safety notes included.

 Make sure that the filter and the compressed air system are free from pressure. If the compressed air

system has to remain under pressure during installation, the shut-off valves have to be protected
against unintentional opening.

 The compressed air source (e.g. compressor) must be safeguarded against exceeding of the maximum

allowable operating pressure using safety equipment.

18

Installation

Suitable place of installation

 The compressed air pipelines must be provided with shut-off valves used for disconnecting the filter

from the piping system. We recommend using shut-off valves with continuous opening behaviour. This
behaviour avoids sudden pressure equalisation between the piping sections.

 In the event that operation cannot be interrupted for maintenance purposes, we recommend in-

stalling a bypass line around the filter.

 The pipelines must be suitable for use with the maximum possible operating pressure.
 The connection points have to be compatible with the filter inlet and outlet with regard to nominal

width, nominal pressure and type. (→ See general arrangement drawing in the appendix)

 Any vibrations or pulsation must not be transmitted to the filter via the pipelines. This may damage

the filter and the accessories. If required, install compensators or pulsation absorbers in the pipelines
to be connected.

 Wet pipelines upstream of the filter should be installed at a slope in order for the liquid condensate

(water and oil) in the line to be discharged in flow direction. If installation of an upright pipeline with
upward flow is inevitable, a condensate drain must be provided at the lowest point of the pipeline.
This avoids condensate from being accumulated in the pipeline and suddenly being swept away by the
compressed air flow. These kinds of water shocks may damage the filter and must be avoided.

 Install a valve in the piping system which can be used for depressurising the filter. Also install a pres-

sure gauge which indicates the pressure in the filter.

 Install the filter in upright position.
 Consider the direction of flow! The direction of flow is indicated by means of an arrow on the housing.

(→ page 14)

 Keep an adequate distance to walls and other system parts around the filter.
 Make sure to provide adequate space below the filter in order to replace the filter element easily. (→

For details on the height that should be available for replacement, please refer to the appendix.)

 Prior to closing the connected pipelines, please check that there are no objects or contaminations left

in the pipelines.

 The filter is supported by the connecting pipelines. Provide adequate support for the incoming and

outgoing pipelines to carry the weight of the filter even when it is completely filled with liquid.

 When an automatic condensate drain was selected (8, 10, 11), a condensate line between the conden-

sate outlet at the condensate drain and a collecting tank must be installed. The collecting tank must be
exhausted against the atmosphere to avoid pressurisation in the collecting tank.
Connection for condensate line:  drain (8) : ---

 drain (10) : ---
 drain (11) : G1/4“ female

When using the hose nipple on the condensate outlet, secure the hose using a hose clamp.
Make sure the condensate line is appropriately pressure-proof.

 When checking the installation for leaks the maximum allowable operating pressure of the filter must

not be exceeded. (→ See specification on the type plate, page 10)

 Check all the components for visible damages. If there are defective components, commissioning of

the filter is not permitted.

In most applications the compressed air cools down while passing the piping system. As a result,
moisture condenses from the compressed air. To obtain optimum filtration performance the filter
should therefore be installed at a place in the piping system that is as cold as possible.
Often, the best location for installing the filter is directly upstream of the system part that is to be
protected by the filter (e.g. compressed air dryer or compressed air distributor).

19

Installation

DANGER !

– Overpressure

CAUTION !

– Pressure blows and overload

7. Commissioning

The filter is under pressure.
Suddenly escaping compressed air may result in serious injury.
Do not carry out mechanical work on the filter as long as the filter is under pressure.

Once installed the filter is immediately ready to operate and may be pressurised.

If all conditions required for commissioning are fulfilled, the commissioning procedure can be started. Perform
the following steps in the listed order.

7.1 Pressurisation of the filter

Pressurise the filter as follows:

Rapid opening of the valves may cause pressure blows and increased flow rates in the filter. Pres­sure blows and increased flow rates may lead to damages of the filter.
Open the valves very slowly and make sure that the flow noise does not become too loud. Pay
special attention when opening valves that can be opened rapidly by means of a pivoting move­ment.

1) Make sure that the filter is completely closed. There must be no gap between the upper filter part

(1) and the filter bowl (2) when the filter is closed. (→ page 26)

2) Make sure that the accessories are securely installed.

3) Make sure that the compressed air system upstream or downstream of the filter inlet is under

pressure. If necessary, the compressor must be started.

4) Open the valves upstream and downstream of the filter very slowly until hearing the first clear flow

noise. Stop the procedure when the flow noise becomes louder.

5) Check the system for leaks during pressurisation. In the event of leaks, pressurisation must be

stopped and the leaks must be repaired. To repair the leaks the filter has to be depressurised again.
(→ page 21)

6) If flow noise and a pressure increase are no longer present when further opening the valves, they

can be opened completely.

7) Air can now freely flow through the filter.

20

WARNING !

– Exhausting compressed air

Condensate drain type

OPEN

8. Decommissioning

Commissioning

Compressed air exhausting to the outside is very loud and may carry small particles.
This may cause hearing damage as well as injuries of the eyes and of the skin.
Close the openings used for releasing the pressure by means of a silencer suitable for the pressure,
if necessary. Open the valves for releasing the pressure only very slowly.
Always wear eye and hearing protectors when working in the vicinity of the filter.

1) Close the valves upstream and downstream of the filter.

2) The filter has now been shut down.

3) Prior to working on the filter it has to be depressurised. For this purpose, open a valve (customer

scope) installed in the piping system and observe a pressure gauge (customer scope). Wait until the
pressure on the pressure gauge has dropped to 0 bar.
Depending on the filter configuration you have the option to open the manual drain valve (7).
When using an electronic condensate drain the pressure can usually only be reduced until reaching
a system-dependent residual pressure. For further information, please refer to the operating man­ual of the condensate drain.

Attention: The valves on the filter and on the condensate drains are not suitable for depressurising
large volumes. For this purpose, we recommend a valve to be installed in the piping system (cus­tomer scope).

7

CDM15/50N

21

Maintenance and repair

DANGER !

– Overpressure

WARNING !

– Exhausting compressed air

CAUTION !

– Qualification and experience required

9. Maintenance and repair

The filter is under pressure.
Suddenly escaping compressed air may result in serious injury.
Do not carry out mechanical work on the filter as long as the filter is under pressure.

Please observe the following requirements for maintenance:

Please observe the following when completing maintenance work:

Compressed air exhausting to the outside is very loud and may carry small particles.
This may cause hearing damage as well as injuries of the eyes and of the skin.
Close the openings used for releasing the pressure by means of a silencer suitable for the pressure,
if necessary. Open the valves for releasing the pressure only very slowly.
Always wear eye and hearing protectors when working in the vicinity of the filter.

Persons working on and with the filter have to be qualified personnel who, because of their quali­fication and experience, are familiar with handling compressed air systems. If you are not experi­enced in using these systems, please ask the relevant experts for help. We recommend that com­missioning and maintenance be carried out by a compressed air specialist company.

 Observe the notes in section "Intended use". (→ Page 7)
 Observe the "Safety notes" and the "General safety notes" in particular. (→ Pages 10, 13)
 Provide the required spare parts. Only use genuine spare parts of the manufacturer.

The manufacture provides prepared spare part packets. (→ Page 4)

 Maintenance must only be carried out if the filter is depressurised. (→ Page 21)

 Make sure that all the connections are tight and sealed.
 Make sure that the filter is completely closed. There must be no gap between the upper filter part

(1) and the filter bowl (2) when the filter is closed. (→ Page 26)

 Carry out a leak test.
 Commission the filter as described on (→ page 20).

22

Maintenance and repair

17 bar to

50 bar

5 bar to 16 bar

9.1 Regular maintenance intervals

The following table provides an overview of the maintenance activities to be carried out routinely. The
maintenance activities are described in detail on the following pages.

Component Maintenance activity

Every month

Every day to every week

becomes worse

Every three months /

or when the residual oil content

becomes worse

Every six months /

or when the residual oil content

mbar at the latest

Every 12 months /

or at a differential pressure of 500

Every 12 months /

or at a differential pressure of 350

See page

mbar at the latest

Condensate drain

Differential pressure

gauge (option)

Filter element for

activated carbon filter

Filter elements at

operating pressure of

Filter elements at

operating pressure of

Water separator

* = Maintenance information can be found in the separate operating manuals of these components.

** = Significantly reduce the maintenance intervals at compressed air temperatures above 35°C

Visual check and func-

tion monitoring

Visual check and func-

tion monitoring

Replace filter element ** 24

Replace filter element  24

Replace filter element  24

Clean insert and

filter bowl





24 *

24 *

When required

23

Maintenance and repair

9.1.1 Condensate drain (if available): visual check and function monitoring

During operation a coalescing filter permanently separates condensate. When not discharging the condensate
the filter is flooded with condensate and the condensate reaches the compressed air outlet. If the condensate
drain is operating properly, only a small amount of liquid should remain in the condensate drain.

1) Check the condensate drain for external damages.

2) Check the condensate drain for leaks.

3) Activate the manual valve or the test button and check the discharged amount of condensate. After

a very short time compressed air should be flowing out of the condensate drain.

 The condensate drain is blocked or defective and needs to be replaced if there is only a little

amount of condensate and compressed air flowing out.

 The condensate drain is not operating properly if there is a large amount of condensate flowing

out before the compressed air is flowing out. (→ Observe the notes in the operating manual of the
condensate drain.)

9.1.2 Differential pressure gauge (if available): visual check and function monitor­ing

The differential pressure gauge is an indicator for the state of the filter element. The filter elements in the
filters will be clogged over time and thus the compressed air flow is throttled. The differential pressure contin­ually increases. If the differential pressure exceeds 500 mbar, the filter element should be replaced. The filter
element must be replaced after one year at the latest.

1) Check the differential pressure gauge for external damages.

2) Check the differential pressure gauge for leaks.

3) Write down the differential pressure in order to record the contamination level of the filter element

over the time.

 In the event of constant compressed air flows and a constant operating pressure, the differential

pressure should only change little or increase slowly for a long time. Replace the filter element if the
differential pressure increases more rapidly.

 If the differential pressure suddenly drops although the compressed air flow remains constant, the

filter element may have been damaged by a pressure shock.

9.1.3 Replacing the filter element

The filter element in the filter prevents particles and aerosols in the compressed air flow from entering the
system.
The filter element in the filter will be clogged over time and thus the compressed air flow is throttled.
The activated carbon element in the filter is continuously laden with oil vapour and other contaminants. This
results in gradually reduced cleaning performance until the activated carbon finally is saturated. The saturated
activated carbon element needs to be replaced by a new activated carbon element, respectively.
To prevent operating errors from occurring, the filter element has to be replaced regularly according to the
maintenance intervals. (→ Page 23).

24

WARNING !

– suddenly escaping compressed air

OPEN

1) Provide a suitable filter element. The filter element type is specified on the type plate of the filter.

(→ Page 10)

2) Only take the filter element out of its packaging when it is to be inserted. Make sure the working

area is clean. Do not touch the filter element when your hands or tools are dirty.

Opening the filter housing:

3) Depressurise the filter, (→ Page 21)

4) Remove the condensate line from the filter, if installed.

5) Disassemble a large condensate drain, in case it obstructs the access to the filter bowl.

Externally installed condensate drains are supplied with a shut-off valve and a screwed joint with a
cap nut. Open the connection between the shut-off valve and the condensate drain by loosening
the cap nut.

Maintenance and repair

When activated the shut-off valve opens suddenly. If the filter is under pressure and the conden­sate drain has been removed, opening the shut-off valve leads to sudden depressurisation. This
results in a very loud and hazardous compressed air stream which carries small particles and may
cause serious injury. Do not use the shut-off valve between the filter and the condensate drain for
depressurisation.

6) Open the depressurised filter housing by unscrewing the filter bowl (2) anticlockwise from the up-

per filter part. If compressed air flows out of the thread, the opening procedure must be immedi­ately interrupted and the filter needs to be depressurised. (→ Page 21)
Usually, the filter bowl (2) can be removed by hand. In the event of larger filters or filters that have
been operated for some time, it may be necessary to use a conventional spanner wrench. If the fil­ter bowl cannot be opened by these means, please first check whether the filter is still under pres­sure.

1

1

1

2

3

3

2

25

Maintenance and repair

Disposal



Replacing the filter element:

1) Slightly turn and pull the old filter element (3) to remove it from the upper filter part (1).

2) Clean the filter holder and the threads of the housing parts.

3) Replace the O-ring of the filter housing, if necessary. Undamaged O-rings can be used again.

4) Lubricate the filter holder and the threads of the housing parts.

5) Take the new filter element out of its packaging. Insert the filter element by slightly turning and

pushing it into the filter holder.

Closing the filter housing:

6) Close the filter housing by screwing the filter bowl (2) clockwise into the upper filter part (1). Make

sure that the filter element (3) remains securely fixed in the filter holder.

7) Only turn until the two housing parts block noticeably when running onto the end stop. There

should be no gap between the two housing parts through which you would be able to see the
thread of the filter bowl (2).
Only turn until reaching the end stop position. Further turning does not increase the tightness of
the housing.

8) Mount all the parts that have been removed before.

9) Check if all the connections are securely fixed.

10) Recommission the filter as described on → page 20.

A clean filter element can be disposed of with the domestic waste.
However, if the filter element is contaminated with hazardous substances, the type of disposal has
to be determined by the owner of the equipment with regard to the type of contamination.

1

2

26

Errors and measures

CAUTION !

– Qualification and experience required

Error

Reason

Recommended measure

Condensate and oil

Volume flow rate in the filter too high

Compare the operating conditions

High pressure fall in

Closed shut

-

off valves

Check valves and open, if necessary.

Monitoring the compressor

10. Errors and measures

Persons working on and with the filter have to be qualified personnel who, because of their quali­fication and experience, are familiar with handling compressed air systems. If you are not experi­enced in using these systems, please ask the relevant experts for help. We recommend that com­missioning and maintenance be carried out by a compressed air specialist company.

The following table explains the possible reasons for the errors and provides the recommended measures for
remedy.

in the pipeline
downstream of the
filter

the filter


 Operating pressure too low
 Temperature downstream of the filter

lower than upstream of the filter

 Strong fluctuations of inlet temperature
 Defective condensate drain on filter
 Closed shut-off valve between filter and

condensate drain

 Open bypass line
 Connected pipelines downstream of the

filter were already contaminated with oil
during installation or have been contaminat­ed by the previously opened bypass line

 Oil breakthrough on the compressor


 High differential pressure in the filter ele-

ment

 Large amounts of dust and encrustations

block the pipelines



with the specified values and correct
the operating conditions, if necessary.
(→ Page 8)

 Check filter element and replace, if

necessary.

 Check condensate drain for proper

function and correct any malfunctions.

 Make sure bypass line is closed.

Protect it against unintentional open­ing.

 Clean or replace pipelines.
 Monitor the oil consumption on the

compressor and correct any malfunc­tions, if necessary.


 Check filter element and replace, if

necessary.

With oil-lubricated compressors the main source of the oil is in the compressor.
Compressors that are insufficiently cooled and maintained lead to particular high oil load on the
filter.
Regularly check the oil consumption and monitor the oil consumption over a longer period. The
compressor must be maintained at regular intervals.

27

Appendix and technical documents

11. Appendix and technical documents

11.1 General arrangement drawing and filter configuration

The product data sheets can be found on the Internet at: → www.fstweb.de → Download

28