Bofa FumeCAB 1000 iQ User manual

FumeCAB 1000 iQ
USER MANUAL
V1 May 15

Contents
01
02
03
Overview of your iQ extraction system (front)
Overview of your iQ extraction system (back)
Overview of LCD display
1
01
Unpacking and unit placement
3
01
Unit information & connecting to mains
4
01
02
Turning extractor on / Changing display units
Setting the airflow
03
Airflow auto adjust (first installation only)
5
01
02
Important safety notes
Safety labels
2
01
02
Cleaning the unit / Pre filter replacement
Combined filter replacement
6
01
Fault indication / Error codes
8
01
Consumable spares / Filter disposal
9
01
FumeCAB 1000 iQ specifications
10
01
iQ display features / Visual alarms
Visual alarms (cont’d)
7
02
03
USB connectivity / USB upload
04
USB download
05
Information collected by USB

Overview
Company Branding
LCD Display
Control Panel
Filter Door Panel
Hinged Perspex
enclosure panel
Door Latches
Combined Filter
Filter Release Handle
Pre Filter
Air Inlet
01
1

Overview
Motor Cooling
Mains Isolation Switch
Mains Inlet
Inlet for
Tools/Equipment/Cables
Air outlet
USB Port
02
1

Overview
Standby
LCD Display
Airflow Increase/Decrease
Enter
3 Position Rocker Switch to
Adjust Lighting Settings
LCD Display
Real time pre filter
condition
Real time Combined filter
condition
Internal unit temperature 0C / 0F
Motor run hours/
Alarm window
Target airflow set
point
Actual airflow in
CFM or m3/h
Motor status icon
03
1

Safety Instructions
Important safety notes
Concerning symbols used on the extraction unit and referred
to within this manual.
Danger
Refers to an immediately impending danger. If the danger is
not avoided, it could result in death or severe (crippling)
injury. Please consult the manual when this symbol is
displayed.
Warning
Refers to a possibly dangerous situation. If not avoided it
could result in death or severe injury. Please consult the
manual when this symbol is displayed.
Caution
Refers to a possibly harmful situation. If not avoided,
damage could be caused to the product or something in its
environment.
Important (Refer to manual)
Refers to handling tip and other particularly useful
information. This does not signify a dangerous or harmful
situation. Refer to manual when this symbol is displayed.
Electrical Safety
The FumeCab 1000 iQ system has been designed to meet
the safety requirements of the Low Voltage Directive
2006/95/EC (previously numbered 73/23/EEC)
Warning
When working with the pump/motor housing open, Live
230/115 volt mains components are accessible. Ensure that
the rules and regulations for work on live components are
always observed.
Important
To reduce the risk of fire, electric shock or injury:
1. Always isolate the system from the mains power
supply before removing the pump/motor access
panel.
2. Use only as described in this manual.
3. Connect the system to a properly grounded outlet.
Dangers to eyes, breathing and skin
Once used, the filters within the FumeCab 1000 IQ system
may contain a mixture of particulates, some of which may
be sub-micron size. When the used filters are moved it may
agitate some of this particulate, which could get into the
breathing zone and eyes of the operative. Additionally,
depending on the materials being used, the particulate may
be an irritant to the skin.
This unit should not be used on processes with sparks of
flammable materials or with explosive dusts and gases,
without implementation of additional precautions.
Caution: When changing used filters always wear a mask,
safety shoes, goggles and gloves.
Carbon selection
Please note that the media within the gas filter fitted in the
FumeCab 1000 iQ is capable of adsorbing a wide range of
organic compounds. However, it is the responsibility of the
user to ensure it is suitable for the particular application it is
being used on.
BOFA Technical Service
If a problem arises with your FumeCab 1000 iQ system, or if
it displays a fault code, please refer to the troubleshooting
guide section 8of this manual. If the problem is still not
resolved, please:
•Visit our website at www.bofa.co.uk for on-line help.
•Or contact the helpline on [phone], Mon-Fri,
9am-5pm.
Email: [email protected].uk
Serial Number
For future reference, fill in your iQ system details in the
space provided. The serial number is on the rating label
located on the side/rear of the unit.
Serial Number:
01
2

Safety Instructions
Warning and Information labels
The following listing details labels used on your FumeCab
1000 iQ unit.
Goggles, Gloves & Mask Label
Location: Front face of both filters
Meaning: Goggles, Gloves and Masks should be worn while
handling used filters.
Do Not Cover Label
Location: Rear motor cooling panels and left side of unit
Meaning: Do not cover any louvers or holes adjacent to the
label.
Electrical Danger
Location: Upper control panel.
Meaning: Removal of panels with this label attached will
allow access to potentially live components.
Warning Label
Location: Door panel, Perspex door
Meaning: Power should be isolated before the panel with
this label attached is opened/ removed.
Serial Number Label
Location: Top left corner of back panel.
Meaning: This label contains a variety of information about
the extraction unit, including.
•Company name, Address & Contact number
•Extractor model
•Unit serial number
•Operating voltage range
•Maximum current load
•Operating frequency
•Year of Manufacture
•Relevant approval markings/ logos
PLEASE NOTE: If the equipment is used in a manner not
specified by the manufacturer, the protection provided by
the equipment maybe compromised.
Fire Risk Warning
In the very rare event that a burning ember or spark is
drawn into the fume extraction unit, it may be possible that
the filters will ignite.
Whilst any resultant fire would typically be retained within
the fume extraction unit, the damage to the extractor could
be significant. It is therefore essential to minimise the
possibility of this occurring by undertaking an appropriate
Risk assessment to determine:-
a). Whether additional fire protection equipment should be
installed.
b). Appropriate maintenance procedures to prevent the risk
of build-up of debris which could potentially combust.
This unit should not be used on processes where sparks
could occur, with explosive dusts and gases, or with
particulates which can be pyrophoric (can spontaneously
ignite), without implementation of additional precautions
It is essential that nozzles or other extraction/ fume capture
devices and hoses/pipework are cleaned regularly to prevent
the build-up of potentially ignitable debris
02
2

Before installation
Packaging Removal & Unit Placement
Before installation, check the extraction unit for damage.
All packaging must be removed before the unit is connected
to the power supply.
Please read all instructions in this manual before using
this extractor.
1. Move the unit to the location where it is going to be
installed and remove the outer packaging. This unit
should be installed in a well-ventilated area.
2. Open the front door.
Check the filters are located in their correct position
before closing the door and securing the door latches.
Note: The door will not close fully if the Combined filter
has not been secured in place using the internal lever.
(As detailed below)
Ensure that 500 mm space is available around any vented
panels on the extractor to ensure adequate airflow.
Caution
Due to the weight of the extractor suitable lifting
equipment should be used and with regard to
appropriate safety precautions. (See Appendix for
product weight details)
Caution
Under no circumstances should the exhaust
outlet/s be covered as this will restrict the airflow
and cause overheating.
Caution
Do not block or cover the cooling vents on the unit,
as this severely restricts airflow and may cause
damage to the unit.
The FumeCab 1000 IQ features a hinged transparent
Perspex panel on the front of the unit. This allows for more
room to place larger work pieces inside the unit when
working, while not restricting the user’s vision.
The transparent panel can be secured in an open position by
clipping it to the magnet located at the top right corner of
the filter door panel.
01
3

Installation
The FumeCab 1000 IQ has been designed to remove and
filter fume containing potentially hazardous particulate and
gases generated during manufacturing processes. Such
hazardous substances are captured within a multistage
filtration system after which the cleaned air is returned to
the workplace.
The FumeCab 1000 IQ captures the fume acting as an
enclosure or cabinet. The user is working on the work piece
from inside the unit instead of externally through the use of
ductwork.
Specification
Dimensions: Height 1028mm Depth 654mm Width 1000mm
Weight: 120Kg
Voltage: 230V
Frequency: 50/60Hz
Full load current: 12.5A
Power: 1100w
Face Velocity: 0.4 M/Sec
Connection to Power Supply
Please follow the above specification when selecting the
power supply outlet for the iQ system, ensure the power
supply is suitable before connecting the iQ system.
Check the Integrity of the electrical power cable, if the
supply cord is damaged the extraction unit should not be
connected to the mains. The supply cord should only be
replaced by a BOFA engineer as an electrical safety test may
be required after replacement.
The iQ system MUST be connected to a properly
earthed outlet.
Connect the power cable to an isolated electrical supply.
The mains socket should be installed near the extractor it
should be easily accessible and able to be switched On/ Off.
The cable run should be arranged so as not to create a trip
hazard.
Optional Stand
A powder coated mild steel stand/trolley is available as an
optional extra for the FumeCab 1000 IQ. The stand
measures 1010 x 1090 x 740mm and allows easy
transportation on four castors at an ideal working height.
FumeCAB 1000 iQ Conformal Coating
A conformal coating upgrade is available as an optional
extra for the FumeCAB 1000 iQ unit. This involves the
installation of dark coloured magnetic screens and a UV
light inside the working area within the unit to make the
conformal coating application process easier.
ESD Compliant FumeCAB 700
An ESD compliant version of the FumeCAB 1000 iQ is also
available. This unit features an internal anti-static mat with
lead termination points. The unit is also painted in an ESD
compliant paint finish.
01
4

Operation
Turning extraction unit On
There are 2 stages to powering up your iQ extraction unit.
Firstly the main isolation switch must be switched to the
“On” position, the top side of the switch should be
depressed to power the unit.
This will place the extraction unit in Standby mode,
indicated by the front panel power button glowing Red.
To start the extraction unit press the front panel power
button (refer to section 1for switch location) the button will
change from Red to Green indicating the extraction unit is
now fully On.
It is recommended that the rear isolation switch is left in the
On position and the front standby switch is used to toggle
the extractor On / Off.
01
5

Operation
Setting the desired airflow
The iQ system features automatic flow control. This enables
the user to set the required airflow rate, then over time as
the filters begin to block the motor will automatically begin
to increase in speed to compensate for any loss in
performance caused by the added restriction of the partially
blocked filters.
The extractor and all pipe work must be fully
installed and connected before the airflow is set.
To set the airflow
The airflow can be set between 0.4 –0.45 m/s (110v units) &
0.4 –0.5 m/s (230v units).
1. Press and hold the “Enter” (middle) button (Refer
to section 1for button location) for 3 seconds, or
until all 3 button lights flash green.
2. Release the Enter button, the iQ system is now in
set mode. Press either the Up or Down button to
adjust the airflow accordingly.
Real time airflow is displayed on the LCD screen,
Refer to section 1 for Display information)
3. Once you have your desired airflow, leave the
controls, after around 10seconds the flashing
buttons will illuminate constantly to confirm the
airflow is stored.
The set airflow will now be maintained throughout the life
of the filters. When the extraction unit can no longer
maintain the set airflow an alarm will be given, and the
display will indicate which filter should be changed.
1)
2)
3)
02
5

Operation
Airflow Auto Adjust (first installation only)
When first setting the airflow on your new extraction unit
the iQ will detect if the desired airflow is achievable with the
installation that has been connected to the extraction unit.
If the installation is causing too much restriction for the
desired airflow to be reached, the Auto Adjust feature will
be activated. The procedure events are listed below.
1) The 3 buttons will begin flashing Red along with the
airflow setting on the LCD screen.
2) The airflow setting on the screen will drop to display the
highest airflow that can be achieve.
3) The airflow will stabilise, and the buttons will turn green
to show the airflow has set.
03
5

Maintenance
Maintenance UK
It is a legal requirement, under regulation 9 of the COSHH
regulations that all local exhaust ventilation systems are
thoroughly examined and tested at least once every 14
months (typically carried out annually). The approved code
of practice recommends that a visual check should be
carried out at least once a week.
COSHH requires the annual inspection and testing to be
carried out by a competent person and specifies that
documentation results are recorded in a log.
Contact the seller for more information about inspection
and certification.
Maintenance General
User maintenance is limited to cleaning the unit and filter
replacement, only the manufacturers trained maintenance
technicians are authorised to carry out component testing
and replacement. Unauthorised work or the use of
unauthorised replacement filters may result in a potentially
dangerous situation and/or damage to the extractor unit
and will invalidate the manufacturer’s warranty.
Cleaning the unit
The powder coat finish units can be cleaned with a damp
cloth and non-aggressive detergent, do not use an abrasive
cleaning product as this will damage the finish.
The cooling inlets and outlets should be cleaned once a year
to prevent build-up of dust and overheating of the unit.
Replacing Filters
The iQ system constantly monitors the condition of the
individual filters. As the filters block the LCD display will
show the relevant filter symbol filling up. (see section 1 for
LCD details) Each filter symbol fills up in 5% increments,
when the filter icon is filled that particular filter will need
replacing.
Fire Risk Warning
In the very rare event that a burning ember or spark is drawn
into the fume extraction unit, it may be possible that the
filters will ignite. Whilst any resultant fire would typically be
retained within the fume extraction unit, the damage to the
extractor would be significant. It is therefore essential to
minimise this risk by undertaking an appropriate
assessment to determine:-
a). Whether additional fire protection equipment should be
installed.
b). Appropriate maintenance procedures to prevent the risk
of build-up of debris which could potentially combust.
Pre Filter blocking Combined Filter Blocking
A log of the changes should be maintained by the user.
The filters require attention when the display shows the
filter blocked icon/ filter output signal (if fitted) or when the
extractor no longer removes fume efficiently.
All filters are tested to BS3928. A certificate of conformity
for each filter is available on request.
It is recommended that a spare set of filters are kept on site
to avoid prolonged unit unavailability. Part numbers for
replacement filters can be found on the filters fitted in your
system.
To prevent overheating, units should not be run with a
blocked filter condition, or with dust obstruction of Inlets /
Outlets.
75% filter blocked indication
When the filters become 75% blocked the buttons on the
front of the extraction unit will turn from Green to Amber
and if fitted the iQ system will output a signal to indicate
this. At this time it is recommended spare filters are
available as a change may be needed shortly.
TIME
01
6

Maintenance
Pre Filter Replacement
The Pre filter needs replacing when the display flashes
between the 2 images shown below, at this point the
buttons will glow Red and if fitted the filter blocked signal
will be given.
To remove and replace the Pre filter follow the procedure
detailed below.
1. Isolate the electrical supply to the extractor
2. Lift the Perspex panel and clip it into place on the
magnet located at the top right corner of the filter
door panel. Unscrew the two knurled knobs inside
the unit allowing the hinged pre filter to drop
down. Remove the pre filter from the tray and
replace it with a new, unused BOFA pre filter. Once
removed it is recommended that the used filters
are bagged and sealed.
3. Lift the tray back into position and screw the two
knurled knobs back in place. Close the Perspex
panel
Combined Filter Replacement
The Combined filter needs replacing when the display
flashes between the 2 images shown below, at this point the
buttons will glow Red and if fitted the filter blocked signal
will be given.
To remove and replace the Combined filter follow the
procedure detailed below.
1. Isolate the electrical supply to the extractor
2. Undo the catches on the front of the unit and open
the filter door.
3. The Combined filter is the higher of the 2 filters
(refer to section 1for filter location) rotate the lever
below the filter through 180oto lower the
combined filter.
4. Using the handle on the front of the filter, pull it out
of the unit being careful to support it as it comes
free as it is heavy.
5. Once removed it is recommend that the used filters
are bagged and sealed.
6. Slide the new filter into position making sure it is
pushed in all the way.
7. Rotate the lever back through 1800to raise the
filter into position.
8. Close the door and fasten the 2 latches
9. Reconnect the power supply
Both filters MUST be fitted when the extractor is in use, if
the combined filter is not installed correctly the iQ
system will not allow the motor to start.
02
6

iQ System Display
iQ Display Features
The iQ display has the ability to display all the faults
associated with your extraction unit. The image below
shows an example of some of the fault icons that may
appear in the alarm window of the LCD display.
Visual Alarms on the iQ system
The iQ system can visually display a wide range of alarms on
its LCD panel. The visual displays, meanings and solutions
are detailed below. All alarms will trigger the system alarm
interface output signal and the inbuilt audible buzzer, if
fitted/ activated.
Over Temperature Alarm
If the iQ system detects an internal temperature greater
than 60oC then it will automatically shut down the extractor
to prevent damage to components within the extractor.
Once the internal temperature has dropped by 50C the
extraction unit will be able to restart.
To restart the extractor after an over temperature alarm the
unit needs to be placed in Standby mode then powered on
again.
Inlet Blocked Alarm
The iQ system features a 2 stage inlet blocked alarm.
•Partial inlet blockage
•Full inlet blockage
Partial hose blocked alarm
This alarm will become active when the iQ system detects a
part blockage in the installation. The iQ system interprets a
partial blockage as a vacuum spike within the inlet but is
only a partial blockage as the extractor is still able to
maintain its set airflow.
During this time it is normal to hear the motor increase in
speed. The blockage will need to remain in the inlet for over
5 seconds before the alarm is given.
Full Inlet Blockage
This alarm will become active when the iQ system detects a
full blockage in the installation. The iQ system interprets a
full blockage as a vacuum spike within the inlet and is
considered a full blocked as the extractor cannot maintain
the set airflow with the blockage present.
During this time it is normal to hear the motor increase in
speed. The blockage will need to remain in the inlet for over
5 seconds before the alarm is given.
To remove the blockage, isolate the extraction unit from the
mains, locate and remove the blockage then reconnect the
mains supply.
01
7

iQ System Display
Gas Filter monitoring (VOC Sensing)
If the VOC (Volatile Organic Compound) sensing option has
been fitted to your iQ system then this will be constantly
monitoring the exhaust gas of the extraction unit.
If the VOC level in the exhaust exceeds the PPM (Parts per
million) level pre-set at BOFA then the Gas alarm will be
triggered and display the Gas icon as shown below.
Removing the Gas alarm warning
The VOC option is a perfect way to monitor how the carbon
section of the combined filter is performing. Once the
carbon within the filter is saturated the VOC sensor will
alarm. At this point the extractor should be isolated from
the mains and a new combined filter fitted. Once a new
filter is installed the alarm will clear.
Run Safe Feature
To ensure personnel protection and avoid damage to the
unit the iQ system will automatically shut down 5 seconds
after no combined filter is detected. If no combined filter is
fitted the motor will stop and the display will appear as
below.
To resolve this, isolate the unit, fit the combined filter (see
section 6.02) and turn the Fumecab 1000iQ on.
02
7

iQ System Display
USB Connectivity
The iQ system is equipped with a USB drive, that operates
as a 2 way device, as detailed below.
•Duplicating iQ settings
•Download iQ Data
The USB port is located on the top left hand side of the unit.
Duplicating iQ settings (USB Upload)
This USB upload feature has been designed for customers
that have multiple extractors and specific set of parameters
that they wish to duplicate across their iQ extraction units.
The Procedure for duplicating extractor settings is detailed
below.
1. Obtain the memory stick file from the seller (if
specification has been pre-arranged with the seller)
Or download original settings from your master iQ
unit) (Max capacity USB Stick 4GB)
2. Download this file to a blank memory stick
3. Place the iQ system in standby mode (Front power
button glowing Red)
4. Insert the memory stick into the USB slot
5. The LCD display will show “upload” press the
button corresponding to this
6. The display will show a progress complete bar and
when finished a completion “Tick”
7. The USB stick can now be removed from the unit,
the door closed and the extractor turned back On
If the USB upload procedure fails, the screen
will display the symbol shown below.
.
03
7

iQ System Display
Download iQ Data (USB Download)
With this feature the customer is able to download all stored
data within the iQ system, this information can then be used
to keep records of how your iQ system is performing, this is
also very beneficial for the technical team when diagnosing
issues with the extraction system. The following list shows
the information available within the event log.
Downloading iQ Data
To download the information from the iQ system please
follow the procedure below.
1. Obtain a memory stick (Max capacity USB Stick
4GB)
2. Place the iQ system in standby mode (Front power
button glowing Red)
3. Insert the memory stick into the USB slot
4. The LCD display will show “download” press the
button corresponding to this
5. The display will show a progress complete bar and
when finished a completion “Tick”
6. The USB stick can now be removed from the unit,
the door closed and the extractor turned back On
If the USB upload procedure fails, the screen
will display the symbol shown adjacent.
.
04
7

iQ System Display
The iQ system will take a snapshot of the system
performance every 45minutes or if a system adjustment is
made or an alarm is triggered.
Some of the information captured is listed below..
•Date
•Time
•Airflow
•Airflow Set point
•Pre filter % blocked
•Combined filter % blocked
•Inlet % (installation restriction)
•Motor output
•Internal Temperature
•Hours run
•Alarms
•Faults
Date & Time
The date and time will be set as part of the testing stage
with the manufacturer and set to GMT.
Airflow
This column shows the real time airflow through the
extractor.
Airflow set point
Shows the target airflow that has been set by the user, this
will record every time an adjustment is made.
Pre filter % blocked
The display on the extractor will show the pre filter blocking
in 5% increments, but with this downloadable file the pre
filter blockage is shown as an exact percentage of its full
capacity.
Combined filter % blockage
The display on the extractor will show the combined filter
blocking in 5% increments, but with this downloadable file
the combined filter blockage is shown as an exact
percentage of its full capacity.
Inlet % (installation restriction)
Shows the percentage of the iQ system capacity that is
taken up by the installation (pipe work) this value would also
rise if the inlet or pipe work becomes blocked.
Motor output
Shows the percentage the motor is being run at to achieve
the airflow set by the user. This value will increase as the
filters begin to block.
Internal temperature
Shows the internal temperature of the extraction unit, the
sensor is mounted to the main PCB when this sensor
reaches 60oC it will shut down the extractor and a log will be
recorded.
Hours Run
This is a simple hours run counter that will begin from the
first time the extraction is switched on by the user. The
hours run counter will only be activated when the motor is
running.
Alarms
When the iQ system has an issue that requires the user to
act upon this is classed as an alarm, when this occurs a code
will appear in this column, the main alarm codes are listed
below.
Code
Meaning
1
Door Open
4
VOC alarm
16
Over temperature
32
Inlet partially blocked
64
Inlet fully blocked
128
No combined filter fitted
512
Motor failure
2048
System 100% blocked
4096
Combined filter blocked
8192
Pre filter blocked
524288
System 75% blocked
Faults
This column will display a code if a fault with the iQ system
is detected, for analysis of any faults in this column please
contact the BOFA helpline.
05
7

Troubleshooting
Fault Indication
The iQ system intelligently monitors the whole extraction
unit. In the unlikely event of a problem with the extraction
unit please read this section of the manual before
contacting the helpline.
This section contains details on all faults the iQ system is
able to display, these faults are detailed below.
Motor Failure
If the extraction unit develops a fault relating to the motor
then the motor icon on the display will stop rotating and
flash the airflow will read O m3/h.
If the above symbol is displayed power should be isolated
from the extractor and arrangements should be made to
replace the motor.
Internal Power Supply
The extractor is fitted with an internal transformer that
outputs 12V DC providing the iQ system with power.
If the buttons on the front panel are not illuminated or
operational this would indicate a problem with the internal
power supply (provided the main isolation switch is in the
ON position and voltage is proven at this point)
Error Codes on the iQ display
The iQ system is able to self-diagnose problems relating
directly to the monitoring system. Faults are displayed as a
number in the error window within the display.
In the event of an error code being displayed please contact
your local representative or BOFA who will be able to
diagnose the fault and advise on the most efficient solution.
USB diagnosis
For a “Real time” event log of any faults with your iQ system
please see section 7.03 & 7.04 to download a full analysis of
the extraction system.
01
8