Activated carbon filter (ACF) loading stations – G306 and G517 platforms
SIGA supplies automated loading stations for testing activated carbon filters (ACF) since more than 10 years. The tested filters prevent fuel vapours from escaping into the environment in motor vehicles. Our test stations enable OEMs and service providers to ensure that the filters meet the requirements of the regulatory authorities. The systems comply with the requirements of CARB, EPA, CHINA VI and EU Directive 98/69/EC, amongst others. Depending on the configuration, up to four filters can be conditioned simultaneously – including aging, multiple loading and breakthrough testing.
We offer the G306 and G6517 platforms in various sizes, ranging from a system with one AKF station up to four AKF stations. We also offer modules for controlled humidification and for the storage of fuel (G588) and butane (G587).
- Precise mass flow control via MFC
- Butane / nitrogen, fuel vapour / nitrogen and mixed stations.
- Documented procedures in accordance with CARB, EPA, EU 98/69/EC, China VI (others possible)
- 1 to 4 loading modules for 1 to 4 activated carbon filters simultaneously
- Visualisation of ageing processes possible
- Storage systems for fuel and butane
- Permanently technically leak-proof
- Mixed stations for butane and petrol possible
- Explosion protection and safety via ventilation and gas detection system
- Humidification from 30% RH to 70% RH
- All supplied with full documentation, operating instructions and CE certificates
- Annual maintenance in accordance with the maintenance schedule
- Response to service enquiries within one working day
Active Carbon loading station G306 with Butane
Our Butane ACF System G306: An adjustable and precisely metered gas mixture of butane and nitrogen is used for loading. Two MFCs per test module control the gas metering, thereby ensuring optimum test conditions. The loading capacity is determined both by the weight gain of the test filter and by the integrated mass flow.
Pressure testing, purging and the return of the residual volume are carried out automatically, with clear operating instructions provided via the control system.
Our ACF loading station also offers the option of simulating ageing processes in activated carbon filters.
Depending on your test requirements, we offer our ACF systems with between one and four modules. The control and operator terminal is centrally integrated within the control cabinet in all versions.
- Precise mass flow control via two MFCs per station
- Flexible gas mixtures of butane/N₂
- 1 - 4 ACF modules in a single system, depending on requirements
- Documented procedures in accordance with regulatory requirements
- Loading rates between 2 g/h and 93 g/h; other rates available on request
- Loading capacity up to 1.5 times the working capacity
- Visualisation of ageing processes possible
- Purge air flow rate adjustable from 5 to 40 l/min
- Permanently technically leak-proof
- Ex protection via ventilation and gas detection station
The ACF G306-030 loading system allows three ACFs to be loaded simultaneously and independently.
Technical specifications system G306 ACF loading station with butane
| Characteristic | ACF loading stations for butane G306 |
| Dimensions H x D x W (mm) per Module | 1900 x 600 x 800 |
| Dimensions H x D x W (mm) Electronics cabinet | 1900 x 800 x 600 |
| Loading rates per module | 2 g/h to 93 g/h (others on request) |
| Filling media | Butane and nitrogen |
| Purge medium | Unconditioned ambient air; humidity, pressure and temperature monitored |
| Purge air flow rate per module | 5–40 l/min, delivered via a Venturi tube |
| Purging air conditioning option | Precise 30% RH to 70% RH using nitrogen with a bubbler, or coarse control (17% RH to 52% RH) for purge air with option G652 |
| Number of modules | 1 to 4 |
| Breakthrough determination | Balance on reference filter |
| Test specimen weighing range | 7 kg ± 0,6 g |
| Valve actuation | Electric and/or pneumatic; compressed air supply of 5–8 bar required |
| Supply voltage | 230 V / 16 A |
| Exhaust air for purging processes | Up to 40 l/min |
| Leak tightness | < 1E-5 mbarl/s helium; permanently technically leak-tight with regular maintenance, using a clamping ring design and Viton seals |
| Safety | Established explosion protection concept with monitored ventilation, gas detection system and emergency shut-off |
| Design | Separate electrical cabinet, separate ventilated compartments for the test specimen, separate system area |
| Butane and nitrogen supply | Via the internal distribution system—e.g., from the SIGA G588 supply cabinet—butane pressure range 0.7 to 1.5 bar (non-condensing; vapor pressure at 20°C is 1.06 bar!), nitrogen pressure range 1.5 to 3.0 bar |
| Control | Control of test routines via the Tornado measurement programme; system control via a Beckhoff IPC |
| Control interface | Local console with screen, mouse and keyboard for carrying out the measurement routines |
| Throughput capacity | Typical N₂ 60 Nl/h; butane 60 Nl/h; instrument air 3 m³/h; exhaust gas 5.6 m³/h; enclosure extraction 21.1 m³/h for a system with one module (higher for larger systems, though not proportionally so—please feel free to contact us for details) |
| Safety note | The exhaust gas contains butane and forms explosive atmospheres when mixed with air; it must therefore be channelled into a suitable exhaust duct |
System G517 ACF loading station with petrol
The ACF G517 petrol loading station enables activated carbon filters to be loaded with petrol vapours. It looks very similar to the butane loading station, but features an additional bubbler due to a slightly more complex process. This allows a flow of nitrogen to be enriched with petrol vapours.
Similar to the butane loading stations, the petrol loading stations are also equipped with two MFCs per test module. The filling capacity is determined both by the weight gain of the test filter and by the integrated mass flow.
Pressure testing, flushing, the return of the residual volume and the visualisation of ageing processes are carried out automatically, with clear operating instructions provided via the control system.
Depending on your test requirements, we offer our ACF systems with between one and four modules. The control and operator terminal is centrally integrated within the control cabinet in all versions.
As an additional option, our ACF G517 loading station with petrol can be used to loaad with butane as well as petrol.
- Permanently technically leak-proof
- Precise mass flow control via two MFCs per station
- Flexible gas mixtures of butane/N₂ or fuel vapour/N₂
- Documented procedures in accordance with regulatory requirements
- Loading of up to 4 activated carbon filters simultaneously
- 1 - 4 activated carbon filter stations, depending on requirements
- Loading capacity up to 1.5 times the working capacity
- Visualisation of ageing processes possible
- Purge air flow rate adjustable from 5 to 50 l/min
Technical specifications system G517 ACF loading station with petrol
| Characteristic | AKF loading stations for petrol G517 |
| Dimensions H x D x W (mm) per Module | 1900 x 600 x 1000 |
| Dimensions H x D x W (mm) Electronics cabinet | 1900 x 800 x 600 |
| Dimensions H x D x W (mm) Drum cabinet (G587) | 2225 x 1018 x 1550 |
| Loading rates per module | 2 g/h to 93 g/h calibrated for butane (others on request) |
| Fuel loading | Bubbler up to 1 Nl/min of N₂, temperature up to 50°C, heated pipes to prevent condensation |
| Filling media | petrol vapour, butane and nitrogen |
| Purge medium | Unconditioned ambient air; humidity, pressure and temperature monitored |
| Purge air flow rate per module | 5–40 l/min, delivered via a Venturi tube |
| Purging air conditioning option | Precise 30% RH to 70% RH using nitrogen with a bubbler, or coarse control (17% RH to 52% RH) for purge air with option G652 |
| Number of modules | 1 to 4 |
| Breakthrough determination | Balance on reference filter |
| Test specimen weighing range | 7 kg ± 0,6 g |
| Valve actuation | Electric and/or pneumatic; compressed air supply of 5–8 bar required |
| Supply voltage | 230 V / 16 A |
| Exhaust air for purging processes | Up to 40 l/min |
| Leak tightness | < 1E-5 mbarl/s helium; permanently technically leak-tight with regular maintenance, using a clamping ring design and Viton seals |
| Safety | Established explosion protection concept with monitored ventilation, gas detection system and emergency shut-off |
| Design | Separate electrical cabinet, separate ventilated compartments for the test specimen, separate system area |
| Butane and nitrogen supply | Via the house network, e.g. from the G587 supply cabinet from SIGA, pressure range butane 0.7 to 1.5 bar - non-condensing (steam pressure at 20°C 1.06 bar!), pressure range nitrogen 1.5 to 3.0 bar |
| Petrol supply | Storage container with a capacity of up to 6 liters, compatible with drum storage unit G587 |
| Control | Control of test routines via the Tornado measurement programme; system control via a Beckhoff IPC |
| Control interface | Local console with screen, mouse and keyboard for carrying out the measurement routines |
| Throughput capacity | Typical N₂ 60 Nl/h; butane 60 Nl/h; instrument air 3 m³/h; exhaust gas 5.6 m³/h; enclosure extraction 21.1 m³/h for a system with one module (higher for larger systems, though not proportionally so—please feel free to contact us for details) |
| Safety note | The exhaust gas contains butane and forms explosive atmospheres when mixed with air; it must therefore be channelled into a suitable exhaust duct |
System G588 butane and nitrogen storage
SIGA GmbH’s G588 butane and nitrogen storage unit enables the supply of butane or nitrogen to ACF stations; up to two cylinders are provided and the system switches automatically when one cylinder runs out.
- Up to two butane cylinders or one butane and one nitrogen cylinder
- Management of up to two nitrogen cylinders outside the cabinet
- Automatic level monitoring and cylinder switching
- Housed in a safety cabinet with 10 air changes per hour
- Integrated gas detection system
- Permanently technically leak-proof
- Price on request
The G588 gas storage unit for one or two butane and nitrogen cylinders
Technical specifications system G588 butane and nitrogen storage
| Characteristic | System G588 butane and nitrogen storage |
| Dimensionen H x T x B (mm) | 2100 x 610 x 900 |
| Storage capacity | 2 x 50 l Butan + 2 x 50 l Stickstoff (ausserhalb des Schranks) |
| Media | Butane and nitrogen |
| Level monitoring | Weighing scales and pressure |
| Safety | Ventilated F90 safety cabinet for butane gas detection system |
| Air change rate | 10 mal pro Stunde |
| Control | KS98 control unit for monitoring and automatic cylinder switching |
| Power supply | 230 V / 16 A |
System G587 petrol storage
The G587 petrol storage allows petrol to be stored and dispensed from up to two drums. The drums are integrated into a safety cabinet. The G587 petrol storage is designed for use with petrol loading stations that operate directly with petrol vapour. This ensures a low-maintenance and reliable supply of petrol vapour.
- Uninterrupted petrol supply and barrel refuelling
- Housed in a safety cabinet, based on a tried-and-tested design
- Centralised control
- Level monitoring and container switching
- Can also be used for other flammable liquids
- Permanently technically leak-proof
- Price on request
- 10 weeks delivery time
Our G587 petrol storage for loading stations is constructed as a modular system within safety cabinets. A combination of a stationary drum and a refill drum ensures uninterrupted refuelling.
Technical specifications system G587 petrol storage
| Characteristic | System G587 petrol storage |
| Dimensions H x D x W (mm) | 2225 x 1018 x 1550 |
| Storage capacity | Storage capacity: up to 6 x 200-litre drums of fresh petrol and 1 drum of used petrol |
| Delivery rate | From 3 drums, up to 55 l/min from each, using a compressed-air diaphragm pump |
| Media | Petrol |
| Level monitoring | Magentorestrictive float sensor |
| Leak tightness | < 1E-5 mbarl/s helium |
| Safety | Air change rate: 10 times per hour, approx. 50 m³/h |
| Compressed air | 2 bar |
| Control | KS98 control unit or IPC |
| Power supply | 230 V / 16 A |
Humidification module for ACF loading stations
Our system with a single AKF station: optimised for space and cost-effective. A precisely defined gas mixture of butane/N₂ or fuel vapour/N₂ is used for loading – controlled via two MFCs per test module.
- Precise humidity controlled between 10% and 70% RH via an MFC and humidity sensor
- Adjustable humidity and temperature
- Integrated into the loading station’s control system
- Permanently technically leak-proof
- Price on request
- 8 weeks delivery time
The humidification module consists of a bubbler in which nitrogen is humidified with ultrapure water. The bubbler may be heated or unheated. Two MFCs are used to mix dry and humid nitrogen in order to set the desired humidity at the humidity sensor. If necessary, a pipe trace heating system ensures that the humidity remains stable and that no condensation occurs.
Technical specifications humidification module
| Characteristic | Humidification module |
| Flow rate | Up to 40 l/min |
| Humidity range | 0% RH, 10% RH to 70% RH |
| Media | Deionized water, nitrogen |
| Moisture dosing | 2 MFCs, humidity and temperature sensor, heater |
| Control | Integrated into the AKF loading station's control system |
| Leak tightness | < 1E-5 mbarl/s helium |
| Nitrogen inlet | 2 bar to 17 bar before the pressure regulator |
| Compressed air inlet | 2 bar |
| Power supply | 230 V / 16 A |
Technical System Description
Aktiv carbon conditioning system with butaen and petrol
The ACF activated carbon filters used in motor vehicles with petrol combustion engines are loaded and purge in accordance with the US CARB and EPA regulations and EC Directive 98/69/EC.
The systems are designed for the simultaneous loading and purging of up to 4 AKF activated carbon filters for cars:
- Activated carbon conditioning, loading up to 1.5 times the working capacity
- Activated carbon loading until breakthrough
- Activated carbon ageing, multiple loading and purging
Adsorption capacity and loading of the activated carbon:
The ACF for motor vehicles is loaded with a butane/N₂ mixture or a fuel vapour/N₂ mixture until breakthrough occurs. For each loading module, nitrogen and butane are metered in a 50:50 ratio using two mass flow controllers (MFCs). Any other mixing ratios can also be set using these MFCs. The control range of the devices is 10 to 500 Nml/min, which corresponds to a butane flow rate of 1.5 to 75 g/h. The gas mixture is fed to the activated carbon filter (ACF) via a flame arrestor. The outlet of the AKF under test is routed via valves to a further activated carbon filter. This reference filter is placed on a set of scales; a weight increase of 2 grams indicates breakthrough of the ACF under test.
Option 1: Set of scales for the ACF under test; the increase in weight is recorded during loading.
Option 2: Before the test begins, the tightness of the newly fitted hose connection is checked by applying N₂ pressure to each ACF. The butane flow is only released once this pressure test has been successfully passed.
Rinsing and cleaning the activated carbon filters:
To rinse and regenerate the activated carbon filter (ACF), ambient air is drawn through the ACF via a Venturi nozzle. The volume of air drawn in is passed through a particle filter and measured by a mass flow meter. The purge air flow rate is adjustable from 5 to 50 l/min. Control is achieved via the flow rate setting of the suction compressed air. The humidity and temperature of the purge air are measured and analysed.
Option: Adjustment of the purge air humidity within the range of 20 to 80% rH.
Control of AKF activated carbon filters for motor vehicles:
The system is controlled by a modern PC. The software carries out the routines required by the regulations and generates the corresponding documentation. The software is fully configured and tested for the entire user interface.
Safety measures for automotive activated carbon filters:
Hydrocarbon gas detection system; the number of sensing heads used is determined by the number of test modules. In the event of a pre-alarm at 20% LEL, all valves are closed. In the event of a main alarm at 40% LEL, the cabinet containing the ACF activated carbon filters is de-energised.
The gas lines, from butane and fuel through to the ACF, are constructed from stainless steel with compression fittings in the gas mixer and are technically permanently leak-proof. The ACF units to be tested are connected via hoses.
The ACF loading station is designed for operation in Ex Zone 2.
- Optional: Control of humidity during the rinsing cycle
- Fuel vapour can also be used as an option
- Software-controlled with documented logging
