Related Manuals for Sullivan-Palatek POWS 400
Summary of Contents for Sullivan-Palatek POWS 400
- Page 1 Original installation and operating manual EN-US POWS Pure Oil Water Separator > POWS 400 Document: SPPOWS_400_manual_EN_07_2024 02-826 Issued: July, 2024...
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Page 2: Table Of Contents
2.5.8 Use of spare parts, accessories or materials ................12 2.6 Warning notices ........................13 3. Product information ........................14 3.1 Product overview ........................14 3.1.1 POWS 400 ............................14 3.2 How it works ........................... 15 3.3 Type plate ..........................16 3.4 Scope of delivery ........................17 4. - Page 3 Table of contents POWS 400 7.2 Initial commissioning ......................35 7.3 Recommissioning ........................36 8. Operation ............................37 8.1 Warning notices ........................37 8.2 Working during operation ..................... 37 9. Maintenance ..........................39 9.1 Warning notices ........................39 9.2 Maintenance plan ........................40 9.3 Maintenance work .........................
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Page 4: Information On Documentation
Original installation and operating manual POWS 400l 1. Information on documentation This documentation describes all steps necessary for the use of the product and accessories. 1.1 Contact Manufacturer Service and tools 1.2 Installation information and operating manual INFORMATION Copyright protection! The content of this installation and operating manual, in the form of text, images, photos, drawings, diagrams, and other illustrations, is copyright protected by the manufacturer. -
Page 5: Safety
Original installation and operating manual POWS 400 2. Safety 2.1 Use 2.1.1 Intended use The POWS, also referred to as the “product” below, is used to treat compressor condensate from oil- lubricated and oil-free compressors. Physical processes are used to separate oils that can be directly separated from the corresponding water. -
Page 6: Foreseeable Misuse
Original installation and operating manual POWS 400l 2.1.2 Foreseeable misuse Reasonably foreseeable inappropriate use is deemed to have occurred if the product or the accessories are used in any other way than that described in the section “Intended use”. Foreseeable misuse includes using the product or accessories in a manner that is not intended by the manufacturer or suppliers but that may occur due to foreseeable human behavior. -
Page 7: Target Group And Personnel
Original installation and operating manual POWS 400 2.3 Target group and personnel This manual is intended for the personnel listed below who are involved in working on the product or its accessories. INFORMATION Personnel requirements! • Minors are strictly prohibited from working with and on the product and its accessories. -
Page 8: Explanation Of The Symbols Used
Original installation and operating manual POWS 400l 2.4 Explanation of the symbols used The symbols used in the following indicate important and safety-related information that must be observed in handling the product and to ensure safe and optimal operation. Symbol Description/explanation General warning symbol (danger, warning, caution) Warning of pressurized system... -
Page 9: Safety Instructions And Warning Notices
Original installation and operating manual POWS 400 2.5 Safety instructions and warning notices This section provides an overview of all important safety aspects for the protection of persons and for the safe and trouble-free operation of the product and accessories. -
Page 10: Pressurized Systems
Original installation and operating manual POWS 400l 2.5.3 Pressurized systems The following situations may result in serious injury or death: • Contact with fluids that escape quickly or abruptly • Bursting system components • Pressurized hose and pipe whipping as a result of disconnection For the safe handling of pressurized systems, observe the following: •... -
Page 11: Installation
Original installation and operating manual POWS 400 2.5.5 Installation The improper assembly or electrical installation of the product and accessories may result in personal injury and damage to property and impair operation. For safe assembly and electrical installation, observe the following: •... -
Page 12: Handling Hazardous Substances
Original installation and operating manual POWS 400l 2.5.7 Handling hazardous substances Substances contained in the condensate that are hazardous to health and the environment can irritate and damage the skin, eyes and mucous membranes on contact. In addition, condensate contaminated with pollutants must not be allowed to enter the sewerage system, water bodies or the ground. -
Page 13: Warning Notices
Original installation and operating manual POWS 400 2.6 Warning notices Warning notices caution against dangers in handling the product and accessories. Observe the warning notices in order to avoid accidents, personal injury and property damage as well as impairments in operation. -
Page 14: Product Information
Original installation and operating manual POWS 400l 3. Product information 3.1 Product overview 3.1.1 POWS 400 Description / explanation Description / explanation Pressure relief chamber Locking device Fixing screw Collector Connecting pipe Riser duct Clean water tank [10] Filter cartridge... -
Page 15: How It Works
Original installation and operating manual POWS 400 3.2 How it works The condensate is fed from the condensate collection line via the condensate inlet [A] into the pressure relief chamber [1]. In the pressure relief chamber [1], entrained compressed air is separated before the condensate flows through the connecting pipe [3] into the filter cartridge [10]. -
Page 16: Type Plate
Original installation and operating manual POWS 400l 3.3 Type plate POWS 400 M/N: SPREMIER-400GF S/N: 12345678 Year: 07/2024 12,7 l/h / 3.36 gal/h max. 16 bar(ü) / 230 psi(g) 16 bar(ü) / 230 psi(g) +5...+50°C / +41...+122°F amb. 50 kg / 110.2 lbs... -
Page 17: Scope Of Delivery
Original installation and operating manual POWS 400 3.4 Scope of delivery The size and further delivery details are provided in the contractual documents. Image Description / explanation Quick Start Guide Pressure relief chamber Foot Collector 1 x 1 filter cartridge Connecting pipe 17 | 64... - Page 18 Original installation and operating manual POWS 400l Image Description / explanation Filter cartridge Elbow connector with union nut and flat gasket Fixing screw Riser duct End cap Locking device, foot Reference turbidity tube 5 mg/l (5 ppm) / 10 mg/l (10 ppm) 18 | 64...
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Page 19: Technical Data
Original installation and operating manual POWS 400 4. Technical data 4.1 POWS operating parameters Parameter POWS 400 Relative ambient air humidity ≤10 … 80%, without condensate 2000 m Maximum operating altitude above sea level 2187.23 yd 16 bar(g) Maximum operating pressure at condensate inlet 230 psi(g) +5 … +50 °C... -
Page 20: Materials
Original installation and operating manual POWS 400l 4.3 Materials Component Material Filter cartridge Plastic blend and cellulose Pressure relief chamber Polyethylene (PE) Polyamide (PA) Condensate inlet Polypropylene (PP) Stainless steel (VA) Connecting pipe Polyethylene (PE) Clean water tank Polyethylene (PE) Foot Polyethylene (PE) Collector Polyethylene (PE) 4.4 Dimensions [mm] [in] [mm] [in]... -
Page 21: Connections
Original installation and operating manual POWS 400 4.5 Connections Connection Qty. Description / explanation 25 mm (0.98 in) Hose connection, connection for the condensate inlet 13 mm (0.52 in) Hose connection, connection for the condensate inlet G1/2" Connection for the condensate inlet Elbow connector, connection for draining the purified 25 mm (0.98 in) condensate 12 mm (0.47 in) Service valve and hose connection 12 mm (0.47 in) -
Page 22: Assembly Conditions
Original installation and operating manual POWS 400l 4.6 Assembly conditions Observe the following conditions when setting up and selecting the place of installation: • The place of installation must meet the following conditions: 0 Indoors 0 Protected from mechanical loads 0 Protected from splash water 0 Protected from direct sunlight and areas exposed to heat sources 0 Protected from frost... -
Page 23: Transport And Storage
Original installation and operating manual POWS 400 5. Transport and storage 5.1 Warning notices WARNING Insufficient qualification! If personnel have insufficient qualifications, this may result in accidents, personal injury and property damage as well as operating disruptions while working on the product or its accessories. • The work on the product and accessories described in the following may only be carried out by transportation and storage skilled technical personnel and must be documented. -
Page 24: Transport
Original installation and operating manual POWS 400l 5.2 Transport Transportation work Image Description / explanation HIER ÖFFNEN OPEN HERE • Only transport the product and the accessories in their original packaging. • Secure the product and accessories in an upright position on a pallet so that they will not fall or shift during transportation. -
Page 25: Assembly
Original installation and operating manual POWS 400 6. Assembly 6.1 Warning notices DANGER Use of incorrect replacement element, accessories or materials! Use of the incorrect spare parts, accessories or materials, as well as auxiliary and operating materials, may result in death or serious injury. Malfunctions and device failure as well as material damage can occur. -
Page 26: Installation Work
Original installation and operating manual POWS 400l 6.2 Installation work The following prerequisites must be met before carrying out assembly work, and all preparation work must be completed first. Preconditions Tool Material Protective equipment • Adjustable wrench • Sealing material (e.g. PTFE tape) To be worn at all times: for sealing the condensate •... - Page 27 Original installation and operating manual POWS 400 Installation work Image Description / explanation 4. Carefully insert the foot into the installation openings while straightening it at the same time. 27 | 64...
- Page 28 Original installation and operating manual POWS 400l Installation work Image Description / explanation 5. Align the locking device with the heel facing downwards and insert it into the locking device opening in the collector. 6. Press the locking device into the locking device opening as far as it will go.
- Page 29 Original installation and operating manual POWS 400 Installation work Image Description / explanation 7. Place the pressure relief chamber on the foot. 0 Align the connection in the direction of the clean water tank. 8. Install the riser duct between the collector and the clean water tank.
- Page 30 Original installation and operating manual POWS 400l Installation work Image Description / explanation 9. Place the end cap on the filter cartridge and turn it clockwise all the way. NOTICE Filter cartridge insertion! Use of incorrect filter cartridges or incorrect insertion of the filter cartridges can cause damage or leakage to the collector and the filter cartridges. • Before inserting the filter cartridges, check to make sure that the filter cartridge is the right one for the product. 0 The color of the cap at the bottom of the filter cartridge must be identical to the color of the cap in the collector. •...
- Page 31 Original installation and operating manual POWS 400 Installation work Image Description / explanation 12. Check the sealing surfaces in the connecting pipe for damage and dirt. 0 Remove any dirt. 0 If there is any damage, contact Manufacturer’s Service (see section “1.1 Contact” on page 4).
- Page 32 Original installation and operating manual POWS 400l Installation work Image Description / explanation NOTICE Damage due to incorrect hose routing. Incorrect hose routing can result in property and environmental damage, as well as impaired operation. • Route all hoses in the shortest possible way. •...
- Page 33 Original installation and operating manual POWS 400 Installation work Image Description / explanation 20. Screw the supplied elbow connector with the mounted flat gasket clockwise as far as it will go onto the condensate drain of the POWS and position it so that the outlet is pointing downwards.
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Page 34: Commissioning
Original installation and operating manual POWS 400l 7. Commissioning 7.1 Warning notices DANGER Operating outside of permitted limit values! Operating the product and accessories outside of the permitted limit values and operating parameters, unauthorized modifications and changes may pose a mortal hazard or the danger of severe injuries. • Observe the limit values and operating parameters specified on the type plate ... -
Page 35: Initial Commissioning
Original installation and operating manual POWS 400 7.2 Initial commissioning For initial commissioning work to be carried out, the following prerequisites must be fulfilled and the preparatory tasks must have been completed. Preconditions Tool Material Protective equipment • No tool necessary • No material necessary To be worn at all times: Preparatory work Assembly of the POWS is complete. -
Page 36: Recommissioning
Original installation and operating manual POWS 400l Commissioning work Image Description / explanation 4. Slowly open the condensate feed to the POWS. 5. Check all hoses and connections for leaks (see section “9.3.5 Leakage test” on page 49). 6. Commissioning is complete and the discharged condensate is treated by the POWS. 7.3 Recommissioning For recommissioning work to be carried out, the following prerequisites must be fulfilled and the preparatory ... -
Page 37: Operation
Original installation and operating manual POWS 400 8. Operation 8.1 Warning notices DANGER Operating outside of permitted limit values! Operating the product and accessories outside of the permitted limit values and operating parameters, unauthorized modifications and changes may pose a mortal hazard or the danger of severe injuries. •... - Page 38 Original installation and operating manual POWS 400l Preconditions Tool Material Protective equipment • No tool necessary • No material necessary To be worn at all times: Image Description 1. Check the level indicator. The level indicator is flush with the pressure relief chamber: 0 The POWS works perfectly.
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Page 39: Maintenance
Original installation and operating manual POWS 400 9. Maintenance 9.1 Warning notices DANGER Pressurized system! The risk of death or severe injuries exists in case of contact with fast or sudden exiting fluids or due to bursting system parts. • Before starting work, bleed the pressurized system and secure it against unintentional pressurization. -
Page 40: Maintenance Plan
Original installation and operating manual POWS 400l 9.2 Maintenance plan Maintenance Interval Turbidity test of wastewater and documenting the • Weekly result • Weekly Visual inspection • Mandatory in case of a negative result of the turbidity test Replace the filter cartridge and activated carbon mat • If the level indicator’s red marking is visible •... -
Page 41: Turbidity Test Of The Purified Condensate
Original installation and operating manual POWS 400 9.3.1 Turbidity test of the purified condensate Preconditions Tool Material Protective equipment • No tool necessary • No material necessary To be worn at all times: Image Description 1. Remove the reference turbidity tube from the holder and fill it with a water sample from the... -
Page 42: Replace Filter Cartridges
Original installation and operating manual POWS 400l 9.3.2 Replace filter cartridges Preconditions Tool Material Protective equipment • No tool necessary • Filter cartridges To be worn at all times: • Activated carbon mat Preparatory work Provide the required number of new filter cartridges and the activated carbon mat next to the POWS. Remove the plugs from the packaging of the new filter cartridges and place them near the POWS. Image Description / explanation 1. - Page 43 Original installation and operating manual POWS 400 Image Description / explanation 3. Connect the drain valve on the connecting pipe to a collecting container and open the drain valve. 0 Close the drain valve the moment that condensate stops coming out.
- Page 44 Original installation and operating manual POWS 400l Image Description / explanation CAUTION Lifting heavy load! Lifting the full filter cartridge in an ergonomically incorrect manner can result in personal injury. • Lift the full cartridge in an ergonomically correct manner close to your body. • Use two people to lift the full cartridge over obstacles. 6.
- Page 45 Original installation and operating manual POWS 400 Image Description / explanation NOTICE Filter cartridge insertion! Use of incorrect filter cartridges or incorrect insertion of the filter cartridges can cause damage or leakage to the collector and the filter cartridges. • Before inserting the filter cartridges, check to make sure that the filter cartridge is the right one for the product. 0 The color of the cap at the bottom of the filter cartridge must be identical to the color of the cap in the collector. • Insert the filter cartridges vertically and carefully into the collector.
- Page 46 Original installation and operating manual POWS 400l Image Description / explanation 14. Place the end cap on the filter cartridge and turn it clockwise all the way. 15. Remove the cover from the pressure relief chamber and remove the activated carbon mat from the vent of the pressure relief chamber. 16.
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Page 47: Cleaning
Original installation and operating manual POWS 400 9.3.3 Cleaning 9.3.3.1 Warning notices CAUTION Improper cleaning and use of incorrect cleaning agents! Improper cleaning and the use of incorrect cleaning agents could result in slight injuries and health or property damage. -
Page 48: Cleaning Work
Original installation and operating manual POWS 400l 9.3.3.2 Cleaning work For cleaning work to be carried out, the following prerequisites must be fulfilled and the respective preparatory tasks must have been completed. Preconditions Tool Material Protective equipment • No tools necessary • Warm water To be worn at all times: • Cotton cloth or disposable cloth Preparatory work The POWS has been decommissioned. -
Page 49: Visual Inspection
Original installation and operating manual POWS 400 9.3.4 Visual inspection During the visual inspection, check all components for mechanical damage and leaks. Replace damaged components immediately. 9.3.5 Leakage test A leakage test is only possible if the POWS is completely filled with water. 1. Fill the POWS with tap water via the vent until water comes out of the condensate drain. -
Page 50: Consumables, Accessories And Spare Parts
Activated carbon mat, pressure relief chamber Upon request 10.3 Accessories Designation Material number POWS 400 spill protection basin Upon request 900 mm x 800 mm (35.43 in x 31.5 in) Alarm sensor, changeover switch Upon request High pressure relief chamber Upon request Expansion kit, POWS 400 to iPOWS 550 Upon request 50 | 64... -
Page 51: Spare Parts
POWS 400 10.4 Spare parts Designation Material number Pressure relief chamber 25 l (6.6 gal) Upon request Cover, pressure relief chamber Upon request Condensate inlet, rotatable, including fixing screw Upon request POWS 400 clean water tank, 2.5 l (0.66 gal) Upon request Foot Upon request Collector 1 x 1 filter cartridge Upon request Connecting pipe Upon request Reference turbidity tube Upon request Elbow connector with union nut, reducer fitting and flat gasket... -
Page 52: Decommissioning
Original installation and operating manual POWS 400l 11. Decommissioning The POWS must be removed from service for prolonged periods of non-operation, e.g.: • Repairs to the product or accessories • Longer standstill of the entire system due to planned work (e.g. conversion work, major repairs, decommissioning of the overall system) 11.1 Warning notices DANGER Pressurized system! The risk of death or severe injuries exists in case of contact with fast or sudden exiting fluids or due to bursting system parts. -
Page 53: Disassembly
Original installation and operating manual POWS 400 12. Disassembly 12.1 Warning notices DANGER Pressurized system! The risk of death or severe injuries exists in case of contact with fast or sudden exiting fluids or due to bursting system parts. • Establish a safe area around the work area before starting work. - Page 54 Original installation and operating manual POWS 400l Disassembly work Image Description / explanation 1. Cut off the condensate feed to the POWS and divert the incoming condensate into a separate container. 2. Connect the service valve on the clean water tank to a collecting container and open the service valve.
- Page 55 Original installation and operating manual POWS 400 Disassembly work Image Description / explanation 3. Connect the drain valve on the connecting pipe to a collecting container and open the drain valve. 0 Close the drain valve the moment that condensate stops coming out.
- Page 56 Original installation and operating manual POWS 400l Disassembly work Image Description / explanation CAUTION Lifting heavy load! Lifting the full filter cartridge in an ergonomically incorrect manner can result in personal injury. • Lift the full cartridge in an ergonomically correct manner close to your body. • Use two people to lift the full cartridge over obstacles. 6.
- Page 57 Original installation and operating manual POWS 400 Disassembly work Image Description / explanation 10. Remove the hose between the tapping point and the pressure relief chamber. 11. Empty and remove the connecting pipe. 12. Clean the connecting pipe (see section “9.3.3 Cleaning” on page 47). 57 | 64...
- Page 58 Original installation and operating manual POWS 400l Disassembly work Image Description / explanation 13. Empty and remove the pressure relief chamber. 14. Clean the pressure relief chamber (see section “9.3.3 Cleaning” on page 47). 15. Remove and clean the riser duct. 58 | 64...
- Page 59 Original installation and operating manual POWS 400 Disassembly work Image Description / explanation 16. Remove the locking device from the foot. 17. Remove the foot from the collector. Make sure to tilt the foot in the direction of the filter cartridge mount. 18. Empty and clean collector. 19. Dispose of the dismantled components properly (see section “13.
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Page 60: Disposal
Original installation and operating manual POWS 400l 13. Disposal The product and accessories must be properly disposed of at the end of their useful life, e.g. by a specialized company. Materials such as glass, plastic, and some chemical compounds can be recycled or reused. NOTICE Improper disposal! The improper disposal of parts, components, operating and auxiliary materials, and... -
Page 61: Troubleshooting
Original installation and operating manual POWS 400 14. Troubleshooting In the event of any malfunctions which are not described, malfunctions which cannot be eliminated or questions, contact Sullivan‑Palatek customer service, see “1.1 Contact” on page 4. Symptoms Possible cause Measure The level indicator’s red marking... -
Page 62: Notes
Original installation and operating manual POWS 400l 15. Notes 62 | 64... - Page 63 Original installation and operating manual POWS 400 63 | 64...
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