Nederman FilterMax F Series User manual

ENGLISH
INSTRUCTION MANUAL
No. 148546 / 03
2006-10-01
0
1
CAPTURE AT SOURCE
F

FilterMax F 30 FilterMax F 60 FilterMax F 90
0
1
0
1
0
1
CE, Declaration of conformity
Delivery check
IMPORTANT! Safety imformation
Pre-installation
Technical data
Dimensions
Mounting instructions
Mounting the filter cartridges
Compressed air connection
Electrical installation
Accessories, electrical installation
Earth control measuring
Applications
Wiring diagram
Connection of several FilterMax to one system
Connection of 2 or 3 pilot boxes
Fans
Duct dimensioning / System installation
Operating description
Starting the system
Monitoring system, settings
Monitoring system, general descriptions
Monitoring system, fault indications
Service instructions
Trouble-shooting schedule
Spare parts
Accessories
Installation protocol
Service protocol
Service notes
Installation
page
3
3
4
4
4
5
6
7
8
9
9 - 11
12
12
13
14
15
15
16
17
18
18 - 19
20
21 - 22
23 - 25
26 - 28
29
30
31 - 32
33 - 36
37
Starting
Settings
Service
Repair
Operating
Accessories
Protocols
List of contents
2

Declaration of conformity
We, AB Ph. Nederman & Co., declare under our sole
responsibility that the Nederman product: FilterMax F
serial 667 with accessories, to which this declaration
relates, are in conformity with the following directives,
underlying standards or other normative documents:
Directive: 98/37/EC - Safety of machinery
Applied standards EN 292 Part 1,2, EN ISO 4871
Directive: 89/336/EEC - Electromagnetic compatibility.
Applied standards EN 50082-1, EN 61000, EN 55011
and EN 55022
Directive: 73/23/EEC - Low voltage equipment.
Applied standards EN 60204-1,EN 60947-1
Directive: 87/404/EEC - Simple pressure vessels
Applied standards EN 286-1 part 1
0
1
C
D
B
A
E
F
G
D
DELIVERY CHECK
The following modules should be mounted
together to assemble the complete FilterMax F.
When delivered A - C are already assembled
(units shipped by sea may contain more
components).
A. Filter unit (1, 2 or 3 pcs.)
B. Stand
C. Control box
D. Collector (2 x 40 litres or 2 x 100 litres
with stand extentions)
E. Inlet
F. Outlet
G. Filter cartridges
(6 pcs./filter unit)
3
The units should be checked for any
damage that may have occured during
transport. If there is damage or parts
missing, the carrier and your local
Nederman representative should be
notified immediately.
FilterMax F can be supplemented by
a number of accessories (see page 30).
This product is designed to meet the
requirements of the relevant EC directives.
To maintain this status all installation, repair
and maintenance work must be carried out by qualified
personnel using only original spare parts. Contact your
nearest authorised dealer or AB Ph. Nederman & Co. for
advice on technical service or if you require spare parts.
AB Ph. Nederman & Co.
Sydhamnsgatan 2
S-252 28 Helsingborg
Sweden
2006-10-01
Lennart Andersson, Product Manager

Filtration
Operating airflow
Filterarea / filter cartridge
Filter material
Operating temperature
Process air (dry) temperature
Material description
Environment classes *
Compressed air requirements
Compressed air consumption
Compressed air connection
Voltage supply
Protection class
Relay voltage, accessory
Working pressure
Pulse noise
Weight
Basic PW filter: 99% at 0,3 µm (after some time in operation), BIA class C
PTFE filter: 99,9% at 0,3 µm (after some time in operation), BIA class C
1 module: 2400 - 3600 m
3
/h (depending on load and application)
2 modules: 4800 - 7200 m
3
/h (depending on load and application)
3 modules: 7200 - 10800 m
3
/h (depending on load and application)
1 module: 60 m
2
, 2 modules: 120 m
2
, 3 modules: 180 m
2
2 layer polyester / polypropylene
-20°C to +60 °C
0 °C to +60 °C, not condensing
3 mm painted steel (FilterMax FI, FO), epoxy based zinc primer and top coat (FO only))
C2 = low corrosion risk, indoors, unheated air varying temperature (FilterMax FI)
C4 = high corrosion risk, outdoors polluted urban areas and coastal areas (FilterMax FO)
0,6 MPa (6 bar, 87 psi), water and oil free
32 N-litres / cleaning pulse at 0,6 MPa (6 bar, 87 psi)
1/2" R 15, max. 0,6 MPa (6 bar, 87 psi)
100 V, 120 V, 230 V, 50/60 Hz
IP 54
24 V AC, max. 60 VA
0 to -5 kPa, not overpressure
Lp Aeq, 30 s, 50 dB
1 module: 615 kg, 2 modules: 890 kg, 3 modules: 1150 kg
*according to EN ISO 12944
Nederman FilterMax F is designed for collecting and
filtering fume and non-explosive dry dust.
To guarantee the correct function and a minimal service
FilterMax F must only be used for these purposes and
according to the instructions in this manual. The manual
contains important warning directions which have to be
read and followed.
Any functional disorders, especially those affecting the
safety of the machine, should be rectified immediately.
IMPORTANT! SAFETY INFORMATION
4
967
min. 100
min. 5001000
1320
FILTERMAX
20
50
1200
max. 155°
PRE-INSTALLATION
FilterMax FI is for indoor installation.
FilterMax FO is for outdoor installation.
FilterMax F should be located with consideration for easy
handling of the collected dust and for convenience of
service and maintenance.
FilterMax F is usually installed on a reinforced concrete
foundation. However, installation on another structure is
also possible. When calculating for foundation or supporting
structure the following factors should be taken into conside-
ration (see technical data):
• Total weight of FilterMax F
• Max. weight of collected contamination
• Possible wind load
• Possible snow load
IMPORTANT! Location must be clear of all obstructions
such as utility lines etc. Pay particular attention to the
anchor bolt location. Anchor bolts (M16) must extend at
least 60 mm above foundation. If you intend to secure the
unit by using expansion bolts or equivalent fittings, the
concrete floor must be prepared accordingly.
For safe and reliable results assembling
work, electrical installation, use, service
and trouble-shooting should be performed
by qualified personnel. Special training may
also be necessary.
Please contact your nearest authorised
dealer or AB Ph. Nederman & Co. for
technical advice.
TECHNICAL DATA

135
D
ABC
FE
970
1030
130
2270 3190 4120
INLET
1 MODULE
3 MODULES
2 MODULES
OUTLET
1160
G
1515
1690
1320
115
20
50
1180
open angle 155
°
A
B
C
D
E
F
G
H
H
NB!
The height dimensions for the
filter are only valid when using
the 40 litres containers.
2 x 40 litres
containers
In/Outlet inner diameters (mm)
250
-
-
-
2450
3370
-
-
275
315
2375
3300
-
2560
3480
4410
1430
325
400
2440
3365
4290
-
3540
4470
1445
395
500
2565
3490
4415
-
-
4600
1465
445
5
DIMENSIONS

0
1
6
MOUNTING INSTRUCTION
Connect the lifting sling
to 4 cabinet lifting lugs.
Distribute loads equally.
Use schackles,
not hooks on the
lifting sling.
WARNING!
Risk of personal injuries
and/or product damages!
Use approved lifting equipment for
unloading, assembly and installation
of the units.
NB! Maximum 2 units should be
lifted at the same time.
x 3
1. Mount the dust containers. If dust containers
2 x 100 litre should be mounted the stand extensions
also must be mounted.
2. FilterMax is usually anchored to a concrete foun-
dation with expansion bolts or similar. Fit the fixing bolts
and use adjusting pieces, if necessary, to get the filter
unit in level. Check with a spirit level.
For more stabilty, the filter unit can be braced
against the wall.
IMPORTANT!
Ensure that the inlet, outlet and
all filter units always are mounted
together with bolts in all intended
holes. Always use toothed washers
to ensure electric connection.
0
1
3. For FilterMax F 60 and F 90 two and three
filter units are used respectively. Mount the units
together to build the complete filter unit.

MOUNTING THE FILTER CARTRIDGES
1. Unscrew the two fixing screws on the
access door. Use the enclosed T-key or a 10 mm
standard hexagon key. Open the door.
3. Handle the filter cartridges carefully to
avoid mechanical damage to the filter surface.
2. Loosen the nuts
on the filter holders
but don’t screw them
off completely.
Remove the filter
holders.
WARNING!
Risk of personal injury!
For FilterMax F equipped with 2 or 3 modules
(12 or 18 filter cartridges), an approved lifting
platform (see figure) has to be used when
mounting or replacing the filter cartridges.
6. Shut the access door and
fasten the two fixing screws.
5. Hang the filter holders on the screws
and fasten the nuts.
4. Insert the filter
cartridges. NB! The
mark on the back end
cap should be put on
the angled sheet-metal
plate just inside the
filter hole.
NB! The inlet and outlet are reversable
and concequently they can be positioned
for duct connection on the
right or left side of
the filter.
7
4. Fit the inlet and outlet.
(NB! The inlet is equipped with
an inspection cover on top.)

FilterMax F
Control box
Pressure switch
(accessory)
Compressed air tank, module no. 3
Compressed air tank, module no. 2
Compressed air tank, module no. 1
Water drain valve
Connect the compressed air supply line
to the compressed air connection of
the filter. Use pipe sealant on all
compressed air connections.
Compressed air components
(accessories, see page. 30)
A shut off valve for service work and a
filter regulator should be installed in the
compressed air pipe line (Note the flow
direction during the installation).
Important! the filter regulator
must be positioned in a frost free
environment.
Recommended connection size:
minimum 1/2".
Water drain valve
Water drain valve
IMPORTANT!
• The compressed air supply pressure has
to be = 0,4 - 0,6 MPa (4 - 6 bar / 58 - 87 psi).
• The compressed air shall have a dew point
below the minimum temperature at which the
system is ment to be used.
• The compressed air supply must be both oil
and water free.
• Improper air pressure or contamination in
the compressed air can result in cleaning
valve failure, poor cleaning and filter
performance.
• Purge compressed air lines to remove debris
before connecting to the compressed air
manifold.
• Do not use thread-sealing tape after the
filter regulator.
• Quick couplings throttle the air too much
and are not recommended.
• Turn off and bleed off compressed air supply
before doing any service work.
• Do not pressurise the system if the air tem-
perature is below the minimum operating
temperature, that is -20 °C. At lower air tem-
perature the process could be started and be
in operation for a while (approx. 15 min.) after
which the system can be pressurised.
8
Filter regulator,
recommended pressure
0,5 MPa (5 bar / 73 psi)
(accessory)
Service valve with
integrated drain valve
(accessory)
Compressed
air connection
COMPRESSED AIR CONNECTION

Automatic depressuring of compressed air tanks at fire
Frost free
Filter
regulator
Normally closed
valve with big bore.
Normally
opened valve.
Compressed
air connection. Both valves shall be connected to
JP6:4, 10/11, so they will be acti-
vated (drawn) at normal operation.
At a possible fire alarm (or a power
failure) the valves are switching and
the compressed air tanks will be
depressurised.
Compressed
air tank on
FilterMax F
JP1
14 109876532
132
97 98
> P
P > 3 bar
JP6
14 10119876532
External START/STOP
Pressure switch, compressed air Fan starter (24 V AC)
Down time damper (24 V AC)
Alarm signal (A or S), 24 V AC
A-Alarm, potential free
contact, 24 V AC
Fan starter
potential free
contact, 24 V AC
Alarm device
Start contactor
Fan start equipment
Connection block JP 1: Digital inputs
High dust level
Pressure switch, high dP /
low airflow / simple dP control
Fan motor protector
Spare, not used
Pressure switch
Dielectric detector PNP
Connection block JP 6: Outputs
Damper motor
Fire alarm
Dust feeder (24 V AC)
Automatic depressurising of
compressed air tanks at fire
The accessories must be equipped with
a potential free contact
Connecting fan and other accessories to the FilterMax F
as well as connecting the FilterMax F to the mains must
be done by a qualified electrician.
ACCESSORIES, ELECTRICAL CONNECTION
ELECTRICAL INSTALLATION
IMPORTANT!
All electrical work must be done by a qualified
electrician according to local regulations.
Connect FilterMax F to the mains and connect fan and
other components and accessories according to the
following wiring diagrams.
A lockable safety switch should be fitted on the
mains connection cable.
Electrical connection together with Nederman Fan Starter
or Fan Inverter is described on wiring diagrams supplied
with these products.
WARNING!
Risk of personal injury!
Disconnect the electrical power
before servicing any electrical component.
All exposed conductive parts of the electrical
equipment and the machine shall be connected
to the protective earthing (see wiring diagram).
9
Max. 2 A

Motor protector, fan
Push the P-button.
Activated input: JP1: 6
Set OFF, nC or nO with the 0/1-button.
High dust level indicator
Push the P-button.
Activated input: JP1: 3
Set OFF, nC or nO with the 0/1-button.
Push the 0/1-button and OFF, nC or nO comes up on the display.
OFF The selected input is not activated.
nC Normally closed: The selected input is activated.
nO Normally opened: The selected input is activated.
Select NC or NO depending on type of contact on the connected
accessory. Make a note of the setting which has been selected.
10
OFF nC nO
OFF nC nO
Selecting OFF, nC or nO
Push the P-button and the 0/1-button more than 4 seconds.
ACTIVATING THE MENU
The inputs or outputs should be activated when accessories
have been connected. Push the P-button to activate actual
input/output. The LED’s indicate, where appropriate, with
red blinking lights.
The inputs are activated in the following order:
ACTIVATING INPUTS AND OUTPUTS
0
1
1
0
P
P
0
1
1
0
P
0
1
1
0
P
A
B
or nC or nO
or nC or nO
OFF
OFF
Red blinking
Red blinking
Pressure switch, compressed air
Push the P-button.
Activated input: JP1: 2
Set OFF, nC or nO with the 0/1-button.
OFF nC nO
Pressure switch
high dP / low airflow
Push the P-button.
Activated input: JP1: 4
Set OFF, nC or nO with the 0/1-button.
OFF nC nO
0
1
1
0
P
0
1
1
0
P
C
D
or nC or nO
or nC or nO
OFF
OFF
Red blinking
Red blinking