BeaconMedaes dMED 7 Instruction Book
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BeaconMedaes dMED 7 Instruction Book

Dual medical air purifiers
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BeaconMedæs
Dual medical air purifiers
dMED 7, dMED 13, dMED 25, dMED 35, dMED 50, dMED 70, dMED 80,
dMED 100, dMED 145
Instruction book

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  • Page 1 BeaconMedæs Dual medical air purifiers dMED 7, dMED 13, dMED 25, dMED 35, dMED 50, dMED 70, dMED 80, dMED 100, dMED 145 Instruction book...
  • Page 3 BeaconMedæs Dual medical air purifiers dMED 7, dMED 13, dMED 25, dMED 35, dMED 50, dMED 70, dMED 80, dMED 100, dMED 145 From following serial No. onwards: API 048 393 Instruction book Original instructions Copyright notice Any unauthorized use or copying of the contents or any part thereof is prohibited.

  • Page 4: Table Of Contents

    Instruction book Table of contents Safety precautions......................4 ...........................4 AFETY ICONS ......................4 AFETY PRECAUTIONS GENERAL ...................5 AFETY PRECAUTIONS DURING INSTALLATION ....................6 AFETY PRECAUTIONS DURING OPERATION ................7 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description......................9 ...........................9 NTRODUCTION ............................11 IR FLOW ..........................13 AND FILTERS ............................14 DRYER ...........................16...
  • Page 5 Instruction book Operating instructions....................64 Maintenance........................68 ........................68 ERVICE AGREEMENTS ......................68 AINTENANCE INSTRUCTIONS ..........................70 ERVICE KITS ......................70 TORAGE AFTER INSTALLATION ......................71 ISPOSAL OF USED MATERIAL Adjustments and servicing procedures..............72 ....................72 ERVICING THE WATER SEPARATOR DRAIN DD, PD .....................73 P FILTER CHANGE ......................74 UNIT DESICCANT CHANGE ........................74 FILTER MAINTENANCE...

  • Page 6: Safety Precautions

    Instruction book Safety precautions Safety icons Explanation Danger for life Warning Important note Safety precautions, general General precautions All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer.

  • Page 7: Safety Precautions During Installation

    Instruction book • Immediately upon completion of work, remove any contaminated clothing and wash hands (and, if necessary, contaminated tools) in a 2% glutaraldehyde solution and rinse under running water. • A checklist / logbook will be made wherein the installer will mark the adherence of the installation to the commissioning chapter of the instruction book.

  • Page 8: Safety Precautions During Operation

    Instruction book The operator has to make sure that the machine is stopped and that the isolating switch is open and locked before any maintenance or repair. As a further safeguard, persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine.

  • Page 9: Safety Precautions During Maintenance Or Repair

    Instruction book • All hoses and/or pipes inside the machine are in good condition, secure and not rubbing • There are no leaks • All fasteners are tight • All electrical leads are secure and in good order • Safety valves and other pressure-relief devices are not obstructed by dirt or paint •...
  • Page 10 Instruction book 11. Never weld on, or in any way modify, pressure vessels. 12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has elapsed;...

  • Page 11: General Description

    For this application, BeaconMedæs has designed the dual medical air purifier range (dMED 7 up to dMED 145). The dMED takes air from any regular compressor and treats it to become ultra clean. It consists of a number of components, which together, after the commissioning certification, produce air with a quality matching the Pharmacopoeia legislation.
  • Page 12 Instruction book General views dMED, general view Air inlet Water separator (WSD) DD filter PD filter CD dryer QDT+ filter PDp filter Pressure regulator Safety valve 2920 7099 70...

  • Page 13: Air Flow

    Instruction book Air outlet ES-MED controller Important The dual medical air purifier unit (dMED) is designed, manufactured and inspected according to the legislation mentioned. Always consult the local legislation on this topic, since the specifications of the air quality can be different. A dMED unit is considered as an active medical device, relying on a source of electrical energy for its operation.
  • Page 14 Instruction book DD, PD Filter with liquid trap, automatically 12/ 15 Pressure regulator with gauge drained Dust filter Safety valve 1, 8 Flow restriction Non-return valve 2, 9, 20 Pressure transducer Pressure switch Reservoir open to atmosphere QDT1, QDT2 QDT filter (basic version, only with inlet pipe above fluid level activated carbon) / QDT+ filter (activated carbon + CO catalyst...

  • Page 15: Wsd And Filters

    Instruction book WSD and filters WSD and filters in the air flow WSD and filter overview 2920 7099 70...

  • Page 16: Cd Dryer

    Instruction book Water separator with drain (WSD) (1) WSD’s are general-purpose water separators for free water removal from compressed air. Centrifugal force created in the cyclone throws free water (droplets) to the wall, from where it flows down to the bottom of the bowl. The water is automatically discharged when a given level is reached. A drain valve is provided for manual draining of the bowl.
  • Page 17 Instruction book Dryer flow diagram Reference Designation Reference Designation Air inlet Air outlet Inlet selector valve 8, 9 Solenoid valve 3, 4 Desiccant tower 10, 11 Silencer Purge nozzle Pressure gauge Outlet selector valve Operation principle (version without purge control) The operation cycle of the dryer is repetitive and is controlled by a factory-set timer, programmed in the central controller.

  • Page 18: Qdt Filter

    Instruction book Purge control version (available as option) Description: see section Optional equipment. QDT filter Air flow Reference Name Air inlet Air outlet Activated carbon (QDT and QDT+) Catalyst (optional) (QDT+) Description The dried compressed air enters the QDT/QDT+ filter A QDT filter contains active carbon, reducing volatile organic compounds (VOC) and hydrocarbons (odours, oil vapours) to harmless levels.

  • Page 19: Optional Equipment

    Instruction book Optional equipment All responsibility for any damage or injury resulting from neglecting these precautions, or non observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer.
  • Page 20 Instruction book Reference Name Common Phase Neutral Normally closed contact Normally open contact Earthing Voltage-free contacts Extra electric wiring to connect the potential-free contacts and an external test button can be provided. Remove the manual or automatic drain of the water separator (WSD) or filters (DD and PD) before installing the EWD.
  • Page 21 Instruction book • As long as the dew point is below the set point (-54 °C for HTM and -45 °C for HTM2022), the drying tower will remain drying, until the PDP temperature exceeds the set point. On that moment the regenerated tower will start drying the compressed air and the other tower will be regenerated.

  • Page 22: Es-Med Central Controller

    Instruction book ES-MED Central controller Interface, icons and menu structure Interface Control panel ES-MED Item Designation Function Display Shows icons and operating conditioning. Warning LED Is lit when warning is triggered. Service LED Is lit when a service is needed. Operation LED Is lit when the ES-MED is automatically controlling the compressors and dryers Voltage LED...
  • Page 23 Instruction book Bar graph Status Description Idle compressor The compressor is idle and ready to be called. The bar graph is blank. Lead compressor The central controller has assigned this compressor to be the next one to run. This is indicated by a full line underneath the blank bar graph. Called compressor This compressor is running.
  • Page 24 Instruction book Icon Status Description Failed to go on load The pressure switch at the compressor outlet detects a too low pressure when it should not. Overload The motor draws too much current and the overload has isolated the compressor Element temperature The compressor element outlet temperature is too high warning...
  • Page 25 Instruction book Icon Status Description Pressure fault Dryer outlet pressure too low. Manual reset required. Dew point fault Dew point too high. Manual reset required. Pressure and dew Dryer outlet pressure too low and dew point too high. Manual reset point fault required.

  • Page 26: Central Controller (Es-Med) Operation

    Instruction book • Dryer/compressor selection (ES_3): enables the user to view the compressor/dryer submenu. • Compressor overview screen (ES_4): shows an overview of the compressors of the plant with their status. In the example shown, we can see that compressor 1 is running and will be the next to stop, while compressor 2 is stopped and will be the next to start.
  • Page 27 Instruction book The CAN address should be set to 30 and CAN should be set ON Communication profile should be set to Mk4. ES-MED settings After commissioning the plant, the ES-MED control system must be started, see paragraph Starting further in this section.
  • Page 28 Instruction book The number of compressors should be set to the actual number of compressors present on your plant and ES should be set On. Setting the unit of pressure In the Settings - General submenu (full access needed, see above), navigate to <Pressure Unit> and select the desired pressure unit.
  • Page 29 Instruction book Automatic restart In the Settings submenu, the ArAF (Automatic Restart After voltage Failure) submenu is accessible (full access needed, see above). Ex factory, it should be set to Infinite. Contact BeaconMedæs if it is believed these settings should be changed. Other settings The following settings can be found under the ES Master submenu.
  • Page 30 Instruction book Parameter Function Min. Factory Max. Unit setting setting setting Forced time To program the interval at which, if days activated by “System Forced”, the central controller starts a new compressor in case no sequence change has occurred during the interval Remote to local To program the time interval between time...
  • Page 31 Instruction book Testing the alarms Before starting the plant, the alarms can be tested. The 4 alarms will automatically cycle for 3 seconds without actual faults. This can be used to test the transmission to the control room alarm display. Navigate to the following submenu and press the Enter button: When the test icon is greyed out, the plant needs to be stopped first.
  • Page 32 Instruction book Navigate to the compressor screen, go to Commands and select <ES Start>. A spinning circle will appear to indicate that the ES-MED is operating. Stopping and resetting the ES-MED To stop a certain compressor, see section Stopping in the compressor manual. To force all compressors local, the ES-MED has to be put in local mode before being able to stop it.
  • Page 33 Instruction book The spinning circle symbol will disappear, indicating that the ES-MED is not active (controlling the compressors) any more. The compressors are now in Forced Local Mode even though their local/LAN switch may be in LAN position. This allows the operator to do maintenance or troubleshooting on the central controller while pressure is guaranteed by the local compressors.
  • Page 34 Instruction book To restart after having stopped the ES-MED (see above), proceed to paragraph Starting to start the central controller, putting it in charge of the compressors again. Isolating a compressor controller To carry out maintenance on a compressor without transmitting alarms, select the ES submenu from the main menu (requires full access, see above).
  • Page 35 Instruction book Switching the active dryer When an alarm is triggered on the active dryer (pressure or dew point fault) or after 200 operating hours, the dryer will automatically switch to the backup dryer. However, also during normal operation it is possible to switch to the backup dryer.
  • Page 36 Instruction book Resetting the dryer alarm(s) When a dryer fails on low outlet pressure and/or high dew point, the controller will automatically switch to the backup dryer. An icon representing the failure will be displayed on the failing dryer. 2920 7099 70...
  • Page 37 Instruction book In order to switch to this failed dryer again, it needs first to be reset manually. Event history When an alarm is triggered, the full situation (inputs, outputs, time stamp) is logged into the event history. To take a look, follow the following steps: 2920 7099 70...
  • Page 38 Instruction book The event history keeps track of the last 30 events. To store all events, as well as get a more in-depth and graphical history of inputs and outputs (e.g. pressure), the AirConnect option needs to be installed additionally. Please contact BeaconMedæs.
  • Page 39 Instruction book Viewing the input & output status The direct inputs of the central controller (ES-MED) are the pressures measured upstream (dryer inlet) and downstream (line) of the dryer, as well as the pressure at the outlet of the dryer and the dew point. The outputs are the alarms or normal status that are transmitted potential-free to the hospital control room.
  • Page 40 Instruction book Inputs 2920 7099 70...
  • Page 41 Instruction book Settings Dryer outlet Inputs (10) Line pressure Atmospheric dew point (11) Reserve manifold low pressure (- closed) 2nd atmospheric dew point (12) EWD Alarm status side 1 Carbon monoxide (13) Open Carbon dioxide (14) EWD Alarm status side 2 Modify (15) Pressure drop over filters - side 1...
  • Page 42 Instruction book 2nd reserve fault (16) 2nd dew point fault Dryer 1: inlet valve (17) Plant fault Open (18) Plant emergency Closed (19) Reserve fault (10) Dryer 1, exhaust valve vessel A (20) Pressure fault Protections When there is a problem with one of the direct inputs (see previous paragraph), the red warning LED will be lit.
  • Page 43 Instruction book 3. Dryer 1/2 Pressure Alarm Occurs when the pressure of that dryer (dryer 1 or dryer 2) exceeds the predefined limit (high or low) or no read-out signal is obtained. This will cause the system to switch to the backup dryer and will set the current dryer as failed.
  • Page 44 Instruction book Web browser Carry out the following steps to set a custom IP address, gateway and subnet mask. After connecting an ethernet cable between your network and the controller, the plant can be monitored on line when browsing to the set IP address. 2920 7099 70...
  • Page 45 Instruction book 2920 7099 70...

  • Page 46: Controller Alarms And Faults

    Instruction book Controller alarms and faults 3.3.1 Controller alarms and faults When no alarm is active, the normal status is shown and transmitted to the hospital control room. Normal Menu Line pressure Detail Atmospheric dew point Views When an alarm is transmitted to the hospital control room and shown on the central controller (accompanied by the red warning LED on the central controller and - when applicable - also on a compressor controller), a problem needs to be remedied.
  • Page 47 Instruction book 3.3.2 Plant fault Description A fault has occurred which potentially leads to the system performing sub-optimal, and if left unattended could result in pressure loss or a bad dew point. Causes and remedies This alarm can be caused by one of following causes: 1.
  • Page 48 Instruction book One or both sides of the dryer have been set as failed due to bad dew point. Taking into account the precautions of chapter maintenance warning, press the Reset button in the Dryer Overview screen. 8. Dryer pressure fault alarm One or both sides of the dryer have been set as failed due to a failure of dryer outlet pressure (too low or too high).

  • Page 49: Service Menu

    Instruction book Check the service section of this manual to ensure the desiccant is not used beyond its lifetime. Check the dryer gauges to ensure proper operation. Consult chapter Problem solving. • Check the sight-glass of the filters for presence of water and check the filter drains for proper operation. If necessary, check section Problem solving.
  • Page 50 Instruction book Service Depressurize vessels Service plan (10) Drying after service Service maintenance (11) Dryer forced operation 2920 7099 70...
  • Page 51 Instruction book Service maintenance (12) Commissioning Running mode (13) Not activated Service functions (14) Disable plant fault output Service functions (15) Activate service Dryer operation Once the service access key has been entered the dryer can set into different operation modes: 1.
  • Page 52 Instruction book Activate service Remaining time Dryer 1 Activate Dryer 2 Modify • Depressurize vessels To ensure the dryer is fully depressurized before performing any maintenance, this function will activate all exhaust solenoids of the dryer in service mode for the preset time to blow off remaining air still present in the dryer.
  • Page 53 Instruction book Drying after service Activate Remaining time • Dryer forced operation The dryer forced operation function disables the automatic switch over and forces the system to keep on working on the active dryer even though a pressure or dew point should occur. This function will be disabled automatically after a preset time.

  • Page 54: Installation

    Instruction book Installation Dimension drawings 2920 7099 70...
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  • Page 62 Instruction book References on drawings 2920 7099 70...

  • Page 63: Installation Proposal

    Instruction book Reference Description TP 01 Air inlet TP 02 Sampling point TP 03 Air outlet Installation proposal Example of compressor room Reference Name Minimum free area to be reserved for the medical air unit installation • Install the equipment on a level floor, suitable for taking its weight. Provide enough space (approximately 800 mm (31.5 in)) around the air treatment unit (1) for installation and maintenance operations.
  • Page 64 Instruction book • Make sure that only clean parts come in contact with the outlet of the air treatment unit. If this is not the case, this may have an effect on the quality of the air delivered by the unit. This is also applicable for piping and other parts installed after the unit.

  • Page 65: Electrical Connections

    Instruction book Electrical connections General The electrical wiring must comply with the local regulations. The air treatment unit must be earthed and protected by fuses against short-circuiting. Consult the electric diagram delivered with the unit. Before switching on the main power supply, check the voltage requirements in the technical specifications or on the unit’s data plate.

  • Page 66: Operating Instructions

    Instruction book Operating instructions Safety Always observe all relevant safety instructions. Initial start-up To start up the air treatment unit for the first time or after a long period of standstill, proceed as follows: 1. Close the air supply towards the outlet dew point sensor and purge control sensor (if supplied). 2.
  • Page 67 Instruction book Normal start If the dryer has not been used for more than 3 months, refer to section Initial start-up. In all other cases, proceed as follows: 1. Cut off the air supply from the compressor towards the dryer by closing the external inlet valve. 2.
  • Page 68 Instruction book • Regularly check that water is discharged via the drain outlet of the water separator. In case of EWD (optional): Check that no alarm is displayed on the service panel of the EWD (5) and that oil/water aerosols and/or solid particles are discharged via drain outlet (6). The amount depends on the operating conditions.
  • Page 69 Instruction book Stopping To stop the air treatment unit, proceed as follows: 1. Close the external inlet valve between the air receiver and the dMED and the external outlet valve between the dMED and the air net. 2. Let the unit operate for a period without consumption, to depressurize the vessels. 3.

  • Page 70: Maintenance

    Instruction book Maintenance Service agreements Description Since all service and maintenance has to be done by properly certified and trained service personnel, it is strongly advised to check for a service agreement. BeaconMedæs Customer Centres have a range of service agreements to suit your needs: •...
  • Page 71 Instruction book Service kits For overhauling or carrying out preventive maintenance, service kits are available for the desiccant and the filters (see section Service kits). Preventive maintenance schedule Carry out following operations at the interval (period or running hours) which comes first. The longer interval checks must also include the shorter interval checks.

  • Page 72: Service Kits

    Instruction book (1) whichever comes first The lifetime of the desiccant is related to the operating conditions. The scheduled lifetime is only valid when operating in reference working conditions. If the desiccant becomes contaminated due to more severe operating conditions, it will have to be replaced earlier. It is recommended to have the desiccant replaced by a qualified service technician.

  • Page 73: Disposal Of Used Material

    Instruction book Disposal of used material Used filters or any other used material (e.g. desiccant, lubricants, cleaning rags, machine parts, etc.) must be disposed of in an environmentally friendly and safe manner, and in line with the local recommendations and environmental legislation.

  • Page 74: Adjustments And Servicing Procedures

    Instruction book Adjustments and servicing procedures Servicing the water separator drain Water separator drain (WSD) Procedure Once every six months, service the automatic drain assembly: 1. Isolate the water separator from the air net by closing the external inlet and outlet valve of the unit (customer’s installation).

  • Page 75: Dd, Pd And Pdp Filter Change

    Instruction book DD, PD and PDp filter change Filter Procedure Replace the filter elements yearly or every 4000 hours (whichever comes first), or if the pressure drop exceeds 0.35 bar (5.08 psi). Following procedure is valid for the DD, PD and PDp filters: 1.

  • Page 76: Cd Unit Desiccant Change

    Instruction book CD unit desiccant change Desiccant for CD unit Warning To ensure that the unit always produces pharmacopoeia compliant air, only dedicated and genuine spare parts must be used. The installation and maintenance must be done by trained and certified personnel. Pharmacopoeia compliance After carrying out any maintenance or repair work, Pharmacopoeia testing must be done by a local testing company to assure reliable and correct operation of the unit.
  • Page 77 Instruction book Procedure 1. Isolate the filters from the air net. 2. Depressurize the QDT filter by means of the DD or PD filter drains. 3. Uncouple the pipe at the inlet with the flange. 4. Unscrew the head. 5. Remove the spring and the perforated plate. 6.

  • Page 78: Testing The Electronic Drain Valve

    Instruction book Note When replacing the activated carbon and catalyst, make sure that the activated carbon and catalyst are disposed of according to the local regulations. Testing the electronic drain valve Testing The EWD is available as option. Control buttons of EWD 32 Functional test Briefly press the TEST button and check that the valve opens for condensate discharge.

  • Page 79: Problem Solving

    Instruction book Problem solving Air inlet and outlet valve Use only authorised genuine parts. Any damage or malfunction caused by the use of unauthorised parts is not covered by Warranty or Product Liability. Apply all relevant Safety precautions during maintenance or repair.
  • Page 80 Instruction book Condition Fault Remedy Condensate is not discharged Discharge pipe clogged Check and correct as necessary from the separator Drain valve of separator Remove drain valve assembly, clean and malfunctioning check For separator with EWD Consult BeaconMedæs (electronic water drain): EWD malfunctioning Faults and remedies, filters For all references below, consult section...
  • Page 81 Instruction book Condition Fault Remedy Pressure sensors: error signal Electric connection Check connections • • (no measurement) interrupted • Check sensors • Mechanical damage (e.g. too high mounting torque) • Connection plugs not connected • Crack due to incorrect mounting •...

  • Page 82: Technical Data

    Instruction book Technical data Fuse values Attention The indicated fuse value is the maximum value. The cable size used may specify fuses of a lower value. Values Frequency Voltage Fuse specification Maximum fuse value 50 Hz 230 V gL/gG CSA/UL 60 Hz 115 V CSA HRC/UL RK5...

  • Page 83: Reference Conditions And Limitations

    Instruction book Reference conditions and limitations Reference conditions Units Compressed air inlet pressure bar(e) See section dMED data Compressed air inlet pressure psig See section dMED data Compressed air inlet temperature ˚C Compressed air inlet temperature ˚F Ambient temperature ˚C Ambient temperature ˚F Inlet relative air humidity...

  • Page 84: Technical Data

    Instruction book Technical data Data at 7 bar inlet pressure Unit dMED 7 dMED 13 dMED 25 dMED 35 dMED 50 Volume flow at dryer inlet Volume flow at dryer inlet 14.8 27.5 53.0 74.2 105.9 Pressure drop over dryer...
  • Page 85 Oil vapour mg/m³ ≤ 0.1 • Taste and odour free Data at 10 bar inlet pressure Unit dMED 7 dMED 13 dMED 25 dMED 35 dMED 50 Volume flow at dryer inlet 15.6 Volume flow at dryer inlet 14.8 27.5 53.0 74.2...
  • Page 86 Instruction book Unit dMED 7 dMED 13 dMED 25 dMED 35 dMED 50 concentration ≤ 2 • • Pressure dew point °C ≤ -31 • Pressure dew point °F ≤ -23.8 • Oil vapour mg/m³ ≤ 0.1 • Taste and odour...
  • Page 87 Instruction book Unit dMED 7 dMED 13 dMED 25 dMED 35 dMED 50 Regeneration air consumption (average) % 14.1 14.1 13.3 13.3 14.1 Installed power Net mass Net mass Amount of desiccant per vessel (CD) 11.6 15.3 Amount of desiccant per vessel(CD) 18.1...
  • Page 88 Instruction book Unit dMED 70 dMED 80 dMED 100 dMED 145 Pressure dew point °C ≤ -31 • Pressure dew point °F ≤ -23.8 • Oil vapour mg/m³ ≤ 0.1 • Taste and odour free • Remark When the actual inlet pressure or inlet temperature differs from the reference condition, the volume flow will be different.

  • Page 89: European Directives

    Instruction book European Directives 10.1 Instructions for Use Instructions Step Description The dryers can contain pressurized air. This can be potentially dangerous if the equipment is misused. The towers of the dryer consist of an extruded profile, which must only be used as a compressed air vessel and must be operated within the limits specified.

  • Page 90: 10.2 Pressure Equipment Directives

    Instruction book 10.2 Pressure equipment directives Components are subject to the 97/23/EC Pressure Equipment Directive. The drying towers, consisting of extruded profiles, are the only pressure bearing parts of category I. The category according to 97/23/EC of the pressure assembly, as well as the volume, is indicated in Table A (see below).

  • Page 91: 10.3 Medical Devices Directive

    Instruction book 10.3 Medical Devices Directive Components subject to 93/42/EC Medical Devices Directive All components are designed, manufactured and inspected according to the European Directive 93/42/EC annex II and art. 11 par. 3. Overall rating The dMED unit is conform the Medical Devices Directive 93/42/EC category IIb. 2920 7099 70...

  • Page 92: Declaration Of Conformity

    Instruction book Declaration of conformity (1): Contact address: Atlas Copco Airpower n.v. P.O. Box 100 B-2610 Wilrijk (Antwerp) Belgium (1): Contact address: BeaconMedæs Telford Crescent, Staveley, Derbyshire, S43 3PF United Kingdom 2920 7099 70...
  • Page 94 www.beaconmedaes.com...

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