Klimawent ERGO-KOS-AL User manual

1
30.01.2019 extraction rail ERGO-KOS-AL
Use and Maintenance Manual
Extraction rail
ERGO-KOS-AL
Contents:
1. Introductory Remarks......................................................................................................... 2
2. Application........................................................................................................................... 2
3. Reservations of Producer................................................................................................... 2
4. Technical Data..................................................................................................................... 2
5. Structure and Function....................................................................................................... 4
6. Assembly and Start-up ....................................................................................................... 4
7. Operational Use.................................................................................................................10
8. Troubleshooting Guide.....................................................................................................10
9. Maintenance ......................................................................................................................11
10. Occupational Health and Safety.......................................................................................11
11. Transport and Storage......................................................................................................11
12. Terms of warranty.............................................................................................................12
13. Sample of the Declaration of Conformity ........................................................................15
804K08
KOS-AL
30.01.2019/EN

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extraction rail ERGO-KOS-AL 30.01.2019
1. Introductory Remarks
The purpose of the present Use and Maintenance Manual is to supply User with directions wi-
thin the range of application, installation, start-up and the use of the ERGO-KOS-AL extrac-
tion rail.
Installing, start up and operational use are exclusively admissible after getting acquaint-
ted with the contents of the Use and Maintenance Manual.
With regard to continuity of work carried on improvement of our products, we reserve for oursel-
ves the revision possibility of the draft and technological changes improving their functional
features and safety.
Construction of the ERGO-KOS-AL extraction rail meets the requirements of the current state of
technology as well as the safety and health assurances included in:

2006/42/EC Machinery Directive of the European Parliament and of the Council of May 17th,
2006 on machinery –amending the 95/16/EC (recast) /Journal of Laws EC L157 of 09.06.2006, page 24/
Additionally, the appliance meets following harmonized standard:
●
EN ISO-12100:2012
–
“Safety of machinery –Basic concepts, general principles
for design. Risk assessment and risk reduction”
2. Application
ERGO-KOS-AL is designed for extraction of welding fumes at mobile workplaces –for linear wel-
ding of elements of length up to several metres. The system can work with one or two extraction
fans, depending on the quantity of extraction arms (one extraction arm is subordinated to one
fan).
3. Reservations of Producer
A.
Manufacturer accepts no liability for any consequences following from the operational use
that is in contradiction to the purpose of application.
B.
Installing of any additional elements not belonging to the normal device structure (or acces-
sory set) is not acceptable.
C.
Do not undertake any structural changes or constructional modifications on the device on
one’s own.
D.
Protect the flexible elements and the suction ducts from mechanical damage.
E.
Prior to installing, check the load carrying capability of the building structure where the sys-
tem will be mounted. Unstable installing can result in uncontrolled device detachment and
hazard to personnel / people in the vicinity.
4. Technical Data
Table No.1
Self-tightening suction duct
Type
Part. No
Segment
length
[m]
Cross-
section
[cm²]
Unit weight
[kg/m]
KOS-AL
804K08
2 or 4
290
9,7
Trolley
Type
Part. No
Weight
[kg]
OP-ERGO-L
851W10
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30.01.2019 extraction rail ERGO-KOS-AL
ERGO extraction arms
Type
Part. No
Weight
[kg]
Exact dimensions of the
ERGO-LUX and ERGO-
Flex LUX extraction arms
are specified in separate
user’s manuals and cata-
logue cards.
ERGO-LUX-2
811R54
16,2
ERGO-LUX-3
811R55
18,3
ERGO-Flex LUX-2
811R82
6
ERGO-Flex LUX-3
811R83
8
Axial connection
Sort of the connection
Type
Part. No
Diameter
Remarks
for axial
connection
KPC
804K20
160
To connect the suction
duct to the extraction
installation
Duct hanger
Sort of the hanger
Type
Part. No
Remarks
for roof installing
Z
804K29
The hangers should be fastened
to the duct by bolting.
Distances between the hangers
should not be larger than 3
metres.
for wall installing
L
804K27
Terminal stopper
Typ
Nr kat.
Uwagi
STK
804K30
Serves to stop the suction trolley
at the end of the duct.
Duct segment joint
Type
Part. No
KSG
804K21

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extraction rail ERGO-KOS-AL 30.01.2019
Duct end closing
Type
Part. No
Remarks
PZC
804K22
To be installed at the beginning
of the first and at the end of the
last segment of the duct.
5. Structure and Function
ERGO-KOS-AL system consists of subsequent assemblies:
●
self-tightening suction duct –KOS-AL –constructed of segments of lengths 2 or 4 metres,
●
trolley –displacing along the suction duct,
●
ERGO LUX or ERGO FLEX LUX extraction arms –suspended under the suction trolley,
●
fitting pieces and supporting elements –according to the Tab. No.1 “Technical Data”,
During welding the operator displaces the ERGO extraction arm with the trolley along the suc-
tion duct. The suction hood ought to be adjusted at a distance at least ca. 30 cm from the wel-
ding point.
Fig. No.1 –ERGO-KOS-AL rail system for contamination extraction
6. Assembly and Start-up
All the constructional elements of the KOS-AL duct are listed in Table No.1 “Technical Data”.
Installing of the duct ought to be executed in definite height, according to the particular requi-
rements. On the other hand, the installing height must provide sufficient space for convenient
manoeuvring with the ERGO extraction arm above the workplace.
In case of a high ceiling of the process hall, the duct should be installed to the roof trusses
through an intermediate beam (see Fig. No.2).

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30.01.2019 extraction rail ERGO-KOS-AL
Fig. No.2 –
Installing example of the suction duct –through an intermediate beam to
the roof truss in a high ceiling process hall
Because of the high requirements for the installing of the system –these works should be exe-
cuted exclusively by an installing team of the manufacturer or under supervision of an authori-
zed person. There are special guidelines in the Assembly Instructions of the KOS-AL suction
duct and in for the extraction arms.
Installing the trolley on the suction duct:
Slide the OP-ERGO-L trolley into the KOS-AL suction duct –in such a way that:
–
the trolley rollers are displacing on the side guide-rails of the duct profile,
–
two straps of the rubber apron should hold the suction fitting of the trolley from both sides.
Installing of the ERGO extraction arms:
Extraction trolley is equipped with a flange that is identical with the one at the mounting swivel
of the ERGO LUX and ERGO-FLEX LUX extraction arm. The swivel ought to be fixed through
M6 bolts (6 pieces) to the trolley flange.
NOTE:
The extraction arms themselves ought to
be assembled according to their manual /
assembly instruction for extraction arms.
Extraction arms are delivered in a partly
assembled state.
Fig. No 3

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extraction rail ERGO-KOS-AL 30.01.2019
Execution of the complete extraction system based on the KOS-AL self-tightening suc-
tion duct and ERGO extraction arms
According to the chosen extraction fan, the complete extraction system consists of subsequent
elements:
–
Extraction system with a roof fan:
a/
assembly of the KOS-AL self-tightening suction duct and trolley along with the ERGO
LUX or ERGO-FLEX LUX extraction arm,
b/
elements of the extraction system at the suction side of the fan –connecting the self-
tightening duct with the fan,
c/
roof fan.
–
Extraction system with a fan for indoor installing:
a/
assembly of the KOS-AL self-tightening suction duct and trolley along with the ERGO
LUX or ERGO-FLEX LUX extraction arm,
b/
elements of the extraction system at the suction side of the fan –connecting the self-
tightening duct with the fan,
c/
fan,
d/
elements of the extraction installation at the outlet side of the fan –connecting the fan
with the air discharge outlet.
In order to select the fan, carry out the flow resistance calculation for all the elements of
the designed installation.
Flow charts of the extraction arms:
Fig. No.4

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30.01.2019 extraction rail ERGO-KOS-AL
Fig. No.5
Fig. No.6

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extraction rail ERGO-KOS-AL 30.01.2019
Connection between the suction duct and the extraction fan:
The KPC connection (of the KOS-AL duct) ought to be connected with the fan inlet by means
of conduits and fitting pieces type SPIRO spiral-seam duct. The diameters of these elements
should match the assumed duct connections.
It is recommended:
–
to install a silencer type Tbefore the fan inlet –the silencer length ought to be not less
than 500 mm,
–
to connect the inlet and outlet of the fan with the installations by means with a flexible joint.
Flexible joints do not convey vibrations from the fan to the installation. Depending on the type,
the fan has to be installed on the roof on a fan pedestal or on a roof base, in case of indoor ap-
plication –on wall brackets.
Selection of a fan:
a/
For applications with an indoor fan we suggest using the fan WPA-E-N series of fans of
KLIMAWENT S.A. production.
Fig. No.7 –WPA-E-N –Flow charts

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30.01.2019 extraction rail ERGO-KOS-AL
Tab No. 2 –WPA-E-N –Technical Data:
Type of the fan
Synchronous
rotations
[r.p.m.]
Supply
voltage
[V]
Motor
rate
[kW]
Ingress
protection
IP
Acoustic
pressure level
[dB(A)]
from distance
Maximum
volume flow
[m3/h]
Maximum
vacuum
[Pa]
Weight
[kg]
1m
5m
WPA-3-E-1-N
3000
230
0,25
54
78/70*
64/56*
1160
940
12
WPA-3-E-3-N
3 x 400
WPA-5-E-1-N
3000
230
0,37
54
76/67*
62/53*
1900
1250
16,5
WPA-5-E-3-N
3000
3 x 400
0,37
54
76/67*
62/53*
1900
1250
WPA-6-E-1-N
3000
230
0,75
54
83/75*
69/61*
2500
1700
21
WPA-6-E-3-N
3000
3 x 400
0,75
54
83/75*
69/61*
2500
1700
WPA-7-E-1-N
3000
230
1,1
54
86/74*
72/60*
3100
1800
23
WPA-7-E-3-N
3000
3 x 400
1,1
54
86/74*
72/60*
3100
1800
WPA-8-E-3-N
3000
3 x 400
1,5
54
88/78*
74/64*
3900
2050
29
WPA-9-E-3-N
3000
3 x 400
2,2
54
91/82*
77/68*
4500
2400
36
WPA-10-E-3-N
3000
3 x 400
3,0
54
91/81*
77/67*
6200
2450
50
WPA-11-E-3-N
3000
3 x 400
5,5
54
97/88*
83/74*
8050
2950
64
WPA-13-E-3-N
3000
3 x 400
7,5
54
99/90*
85/76*
10800
3300
85
a/
For applications with a fan located on the roof we suggest using the fan WPA-D-N series
of fans of KLI-MAWENT S.A. production.
Fig. No.8 –WPA-D-N –Flow charts

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extraction rail ERGO-KOS-AL 30.01.2019
Table No.3
Type of the fan
Synchronous
rotations
[r.p.m.]
Supply
voltage
[V]
Motor
rate
[kW]
Ingress
protection
IP
Acoustic
pressure level
[dB(A)]
from distance
Maximum
volume flow
[m3/h]
Maximum
vacuum
[Pa]
Weight
[kg]
1m
5m
WPA-5-D-1-N
3000
230
0,37
54
73/67*
59/53*
1900
1250
23
WPA-5-D-3-N
3 x 400
WPA-6-D-1-N
3000
230
0,75
54
78/75*
64/61*
2500
1700
28
WPA-6-D-3-N
3 x 400
WPA-7-D-1-N
3000
230
1,1
54
81/74*
67/60*
3100
1800
30
WPA-7-D-3-N
3 x 400
WPA-8-D-3-N
3000
3 x 400
1,5
54
82/78*
68/64*
3900
2050
36
WPA-9-D-3-N
3000
3 x 400
2,2
54
86/82*
72/68*
4500
2400
45
WPA-10-D-3-N
3000
3 x 400
3,0
54
87/81*
73/67*
6200
2450
58
WPA-11-D-3-N
3000
3 x 400
5,5
54
91/88*
77/74*
8050
2950
77
WPA-13-D-3-N
3000
3 x 400
7,5
54
95/90*
81/76*
10800
3300
98
Prior to operational use switch on the extraction fan and make sure that the installation is
functioning properly.
7. Operational Use
Low displacement resistance of the suction trolley and easy manoeuvring with the extraction
arm provide a convenient use of the whole extraction system. By means of the shut-off dam-
per lever, adjust the volume flow of the extracted air, in a way that efficiently eliminates the
fume and dustiness, not causing excessive draft.
During the operational use, the position of the extraction arm and of the shut-off lever can be
changed several times adapting the system to the current needs of User.
Having completed the work close the shut-off damper (in the suction hood), as this will impro-
ve the suction capacity in the second extraction arm.
One suction duct provides operational space for simultaneous function of two extraction arms.
Adjustment of the brakes (in the arm joints), ought to be performed according to the individual
instructions of the subsequent extraction arms.
8. Troubleshooting Guide
Table No.4
Problem
Possible reason
Remedial measure
1.
The extraction arm is falling.
Improperly adjusted frictional
Increase the tension upon frictio-
falling
brake in the joint
nal disks of the brake in the joint
by tightening the adjustment nuts
2.
Drop in the air suction rate
Improper impeller rotation sense
Change the phase connection
along with the increased
of the extraction fan
sequence
noise level of the extraction
The mesh holes of the inlet net
Clean them using a wire brush
installation and arm
are clogged
Suddenly occurring vibra-
Foreign matter / object got stuck
Disconnect the motor and
tions of the fan
within the impeller
remove the object
Impeller failure
Replace the impeller for a new