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The KCF 100 is an oil-water separator designed for the treatment of demulsifiable compressor condensates, ensuring compliance with legal requirements. It is a stationary unit suitable for media and ambient temperatures ranging from 41°F to 140°F. The device is designed to prevent oil-contaminated condensate from entering the sewer system, water bodies, or soil, with a target hydrocarbon concentration in indirectly discharged wastewater not exceeding 20 ppm.
The KCF 100 operates by receiving oil-contaminated condensate under pressure (up to a maximum system pressure of 232 psig). The overpressure is reduced in a dedicated pressure-relief chamber (2) to prevent turbulence within the separation container. The calmed condensate then flows into the filter stage, where it slowly passes through a cartridge (3). Clean water is subsequently discharged through the outlet connection (4). The unit's design ensures reliable condensate treatment, provided that all recommendations and conditions outlined in the manual are strictly followed. The cartridge is specifically designed for most modern lubricants, but if the system produces a stable emulsion, contact with KAESER is advised. An electronically level-controlled ECO-DRAIN condensate drain is recommended for optimal condensate discharge, as manual or time-controlled solenoid valve purging can lead to stable emulsions or overloading of the KCF unit.
The KCF 100 is designed for ease of installation and operation. The installation area requires a sealed floor or collecting basin of at least 18 gallons to contain any untreated condensate or oil in case of damage. The floor surface must be stable and level (maximum inclination 1°) to ensure reliable functioning. Up to four condensate lines can be connected directly to the KCF unit using a multiple inlet adapter, which includes three ½" hose connectors for ECO-DRAIN inflow and one 1" hose connector for the KCF. If more than four feed points are needed, a 1" diameter header (24" above the floor with a slight slope towards the KCF) is required. Condensate should always be fed from the top. The connecting adaptor can be rotated to align with the inflow direction. Hoses must be securely fixed to prevent flapping movements and potential injury or damage. The service valve must remain closed during operation. Before introducing condensate, the unit must be filled with approximately 18 gallons of clean water through the pressure relief chamber until water flows from the outlet. After a 5-minute wait for the cartridge to adsorb water, additional water should be added until the outlet flows again, indicating the unit is recharged and ready.
Regular maintenance is crucial for the KCF 100's optimal performance and longevity. Prior to any maintenance, the condensate inlet must be shut off (and the compressor switched off if necessary). General cleaning of the KCF is recommended every 12 months, which involves emptying and cleaning the main tank. It is critical not to use any cleaning agents (surfactants or flammable cleaners) as they can impair filter efficiency. After cleaning, a new filter set and filter mat must be inserted, and the unit refilled with clean water. Start-up procedures, including filling with water, should be followed after maintenance. The operator is responsible for constant monitoring to ensure the KCF oil-water separator is leak-tight and functioning correctly. This includes regularly checking for leaks and performing a weekly clean water test using the provided condensate testing kit. If the sample is cloudier than the reference, the filter needs to be changed. It is recommended to always keep a spare original cartridge on hand. Only original cartridge sets should be used, as non-original filters can invalidate the general technical approval and require individual approval from local authorities. The plastic bag around a new cartridge must be removed before installation. Never pour any foreign liquid into the pressure relief chamber, as this can impair filter efficiency. All maintenance work must be documented in the operating manual and reports kept available for inspection by the responsible local authority.
General| Brand | KAESER |
|---|---|
| Model | KCF 100 |
| Category | Water Filtration Systems |
| Language | English |
