Teka Caremaster BGIA User manual

Operating Instructions
Type
Caremaster BGIA
TEKA Absaug- und Entsorgungs-
technologie GmbH
Industriestraße 13 D-46342 Velen
Postfach 1137 D-46334 Velen
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
www.teka.me

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Contents
1 Diagram/description of the components ..................................................................................................... 3
2 Preface........................................................................................................................................................ 5
3 Function of the TEKA-CAREMASTER-BGIA ............................................................................................. 5
4 Safety instructions ...................................................................................................................................... 6
5 Commissioning ........................................................................................................................................... 7
5.1 Attaching the extractor fittings ............................................................................................................. 7
5.2 Electrical connection of the unit........................................................................................................... 8
6 Explanation of the controls ......................................................................................................................... 8
7 Maintenance ............................................................................................................................................... 8
7.1 Changing of pre-filter .................................................................................................................................. 9
7.2 Changing of particle filter................................................................................................................... 10
8 Disposal .................................................................................................................................................... 10
9 Technical data .......................................................................................................................................... 11
10 Parts list .................................................................................................................................................... 11
11 Declaration of conformity TEKA-SF-BIA.................................................................................................. 12

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1 Diagram/description of the components
Cartmaster, 1x Suction arm
Pos.1
Pos.2
Pos.3
Pos.4
Pos.5
Pos.6
Pos.7
Pos.8
Pos.9
Pos.10
Pos.11
Pos.12
Power switch
Operating hour counter
Operating status lamp: green
Volume flow control lamp: red
Signal horn
Suction arm with suction hood or
connecting piece
Lid
Hand grip
Filter housing
Filter door
Ventilator housing
Ventilator door
Pos.13
Pos.14
Pos.15
Pos.16
Pos.17
Pos.18
Pos.19
Pos.20
Pos.21
Pos.22
Pos.23
Pre-filter tray
Pre-filter element
Particle filter
Lifting device
Lock for lifting device
Castor with brake
Castor
Bolt for attaching arm
Washer for attaching arm
Rotary flange
Mains supply cable with mains
connector

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Cartmaster, 2x Suction arm
Pos.1
Pos.2
Pos.3
Pos.4
Pos.5
Pos.6
Pos.7
Pos.8
Pos.9
Pos.10
Pos.11
Pos.12
Power switch
Operating hour counter
Operating status lamp: green
Volume flow control lamp: red
Signal horn
Suction arm with suction hood or
connecting piece
Lid
Hand grip
Filter housing
Filter door
Ventilator housing
Ventilator door
Pos.13
Pos.14
Pos.15
Pos.16
Pos.17
Pos.18
Pos.19
Pos.20
Pos.21
Pos.22
Pos.23
Pre-filter tray
Pre-filter element
Particle filter
Lifting device
Lock for lifting device
Castor with brake
Castor
Bolt for attaching arm
Washer for attaching arm
Rotary flange
Mains supply cable with mains
connector

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2 Preface
One sector of extraction equipment has become very significant in recent years. The filtering of
extracted pollutants and the recycling of filtered air to the working area.
This is a surely a sign that the environmental consciousness of every one of us has altered very
strongly in favour of our environment. For a long time now, no one has denied that pollution occurs
during production. However, the pollutants depend on the process that is used. One can basically
distinguish between gases and fumes (smoke). Fumes could also really be described as dust. If
you examine this dust under a microscope, you will find that they consist of very fine particles, often
with a size of 1 µm or smaller, that can enter the lungs.
The classical method of trying to improve the working conditions of polluted workplaces is general
ventilation. In this case, the general rule is a multiple change of air in the workshop, i.e. the
complete volume of air in the workshop is replaced. However, this method only achieves a small
reduction in the level of pollution within the breathing space of the user.
The same applies to “overhead” extraction, i.e. the installation of large extractor hoods above the
workplaces. This is the worst airflow imaginable, since the pollutants first pass through the
breathing space of the user, and only afterwards are they contained and extracted. This is surely
not the point of the exercise. A much more effective method than overhead/wide-area extraction is
the removal of pollutants directly at their source, with localised extraction. Both the investment and
the operating costs are much, much lower if localised extraction is used.
The environmental and workplace-safety measures are especially important requirements for
succesSF-BIAul application of a technology, in addition to the technological optimisation of the
processing method. In a time of increasing sensitivity and tougher legislation, the task therefore lies
in making an early assessment of the potential hazards for the workplace and the environment, and
reducing them as appropriate.
3 Function of the TEKA-CAREMASTER-BGIA
The TEKA–CAREMASTER-BGIA filter unit is primarily used for localised extraction of dust and
smoke particles. For this purpose, the unit can be equipped with one arm.
Limits of application:
welding fumes with oil mist, aluminium dust, gases, water etc.
(If you are uncertain, please contact the manufacturer!)
The polluted air is sucked into the extractor hood (or application-specific fitting) and transported
through the extractor arm (or extractor hose) to the filter unit. Here, the coarse dust particles are
collected in the pre-filter mat (Pos.14). The subsequent particle filter (Pos.15) traps extremely fine
dust particles with an efficiency of better than 99%. The clean air passes the fan and the noise
attenuation module and returns upward into the room via the exhaust grid. The filtered air is then
sucked in by the ventilator and recycled to the air in the workshop through the exhaust grille at the
back of the unit.
Caution:
As soon as the resistance to the air flow from the accumulated dust particles on the filter cartridge
markedly effects the suction performance, the filter elements shall be exchanged.
(refer to chapter 7.1: “Changing of pre-filter mat“ , chapter 7.2: “Change of particle filter“ )

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4 Safety instructions
When using electrical equipment, the following basic safety rules must be observed, for protection
against electric shock, injury, or fire hazards.
•Before using the equipment, read and observe these instructions!
•Keep the operating and maintenance instructions in a safe place!
•Never use the equipment to extract easily inflammable or explosive gases!
•Do not employ the unit for setting it in explosive zones, e.g. zone 0, zone 1, zone 2, zone 20,
zone 21, zone 22!
•Do not employ the unit for sucking off burning or glowing materials, e.g. cigarettes, matches,
metallic types of dust and/or splinters, paper, cleaning cloths, etc.!
•Do not employ the unit for sucking off burning and/or inflammatory materials, e.g. oils and/or oil
mist, fats, parting agent (e.g. silicone spray), cleaning agent, etc.!
•Never use the equipment for the extraction of corrosive substances!
•Never use the equipment for the extraction of burning or glowing material!
•Never use the equipment to suck up any kind of liquid!
•Do not use the equipment for the extraction of organic substances without written approval from
the manufacturer!
•Protect the connectors from heat, moisture, oil, and sharp edges!
•Keep to the permitted supply voltage! (Observe the data on the nameplate!)
•Use only TEKA replacement parts!
•Do not operate the equipment without a filter insert!
•Disconnect the supply voltage before opening the filter unit!
•The exhaust vent must not be covered up or blocked!
•Always take care that the unit is standing in a stable position, and that the brakes on the castors
are on!
•The filter unit must be disconnected from the mains supply voltage before cleaning or
maintenance, replacing parts, or a functional conversion!
•The filter inserts cannot be regenerated!
•Dispose of the filter inserts in accordance with the regulations!
•If an energy-saving automatic start/stop is being used, the earthing cable must be checked for
possible damage before every welding session.
•The unit must not be used if the earthing cable is not in perfect condition.
•If external filter controls are used, the control cable must be checked for possible damage
before every operating session.
•The unit must not be used if the control cable is not in perfect condition!
•The mains supply cable for the unit must be checked regularly for possible damage!
•The unit must not be used if the mains supply cable is not in perfect condition!
•Do not use the filter unit if one or more of its components are faulty, missing, or damaged. In
any of these cases, please call the TEKA service department on ++44-(0) 151-2874775.

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•When extracting carcinogenic welding fumes as from the processing of nickel or chrome alloys,
the requirements of the directives on clean air of the German TRGS 560 ‘Return of process air
when working with carcinogenic media’ must be observed. (And/or the equivalent national
directives for the respective user.)
Further information regarding the TRGS 560 can be obtained from the
‘BIA - Berufsgenossenschaftliches Institut für Arbeitssicherheit’
( Institute for work safety of the employers’ liability insurance )
D-53754 Sankt Augustin, Germany.
5 Commissioning
The filter unit is supplied with all connections.
The extractor fittings and possibly other accessory equipment, must be installed or mounted on the
unit before commissioning.
5.1 Attaching the extractor fittings
The extractor fitting (e.g. an extractor hose or an extractor arm) must be mounted on the extractor
spouts or the housing cover.
If an extractor arm is used, it is attached by using the flange ring (Pos.22), bolts (Pos.20) and
washers (Pos.21) that are provided.
Warning:
Please take care that the spout is now able to rotate.

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5.2 Electrical connection of the unit
•Connect the filter unit to the mains supply.
(Observe the data on the nameplate!)
•Connect the ventilator to the mains supply via a motor circuit-breaker or a star-delta connection.
If the motor runs in the wrong direction (reduced suction output) then disconnect the ventilator
from the mains supply (pull out the plug) and change over to two phases at the infeed to the
circuit breaker or the star-delta connection. (please comply with the data given on the
nameplate!)
Warning:
Work on the electrical sections must only be carried out by qualified and authorized personnel.
(Observe the data on the nameplate!)
6 Explanation of the controls
Pos.1 The main switch switches the filter unit on or off.
Pos.2 The operating hour counter starts to count as soon as the filter unit will be switch on.
Pos.3 The operating status lamp shows if the filter unit will be switch on.
Pos.4 The indicator lamp for flow volume shows whether the suction power is adequate. If it
lights up, the filter inserts must be replaced.
Pos.5 The signal horn shows whether the suction power is adequate. When releasing acoustic
signal, the filter inserts must be replaced.
7 Maintenance
The accumulation of extracted particles on the filter cartridge will eventually lead to a reduction of
the suction / extraction performance.
The mechanical filter element ensures that more than 99% of the extracted pollutants are retained
in the filter. This also applies to a partially or fully saturated filter. However, the extraction
performance of the filter unit will decrease as the filter elements becomes saturated more and
more.
The pre-filter (Pos.14) must be changed at regular intervals. (Refer to chapter 6.1 ‘Changing of pre-
filter element’)
When the internal resistance of the filter element has increased due to the accumulation of the
separated dust particles and the extraction performance of the filter unit decreases as a whole, the
particle filter (Pos. 15) must be changed. (Refer to chapter 6.2 ‘Changing of particle filter element’)

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Caution :
When changing the filter cartridge, the operation of the filter unit must be interrupted. Exchange of
the filter cartridge and the disposal of the element may be executed only in amply ventilated
environments and when using an appropriate protective respiratory mask. We recommend to use a
respiratory mask to DIN EN 141/143 - Protection class P3. The job of changing the filter elements
should be executed by trained personnel only. Filter disposal according to pertinent directives on
special waste handling. Manually beating the filter element, washing or air jet blasting will destroy
the filter media. As a result the pollutants will be blown into the room.
7.1 Changing of pre-filter
The pre-filter mat (Pos.14) must be changed after a certain number of operating hours. The time
depends on the amount of accumulated dust. At the latest, the filter mat must be changed when
changing the particle filter.
The procedure is a follows:
•Disconnect the filter unit from the mains power supply.
•Open the air filter access door (Pos.10).
•Lower the lifting mechanism (Pos.16) by turning the lock screw (Pos.17) downward.
•Pull out the pre-filter tray (Pos.13).
•Take out the pre-filter mat (Pos.14).
•Install the new pre-filter mat.
Caution :
Only use original TEKA pre-filter elements.
•Insert the pre-filter tray (Pos.13).
•Raise the lifting mechanism (Pos.16) by turning the locking screw (Pos.17) until the pre-
filter tray (Pos.13) sits tight. (At this time check the sealing gasket under the lid (Pos.7) for
possible damage.
•Close the filter access door (Pos.10).
Connect the filter unit to the mains circuit.
(Refer to the data on the type plate)

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7.2 Changing of particle filter
When the extraction performance decreases, the particle filter must be changed according to the
following procedure:
•Disconnect the filter unit from the mains power supply..
•Open the filter access door (Pos.10).
•Lower the lifting mechanism (Pos.16) by turning the locking screw (Pos.17) downward..
•Pull out the particle filter (Pos.15).
•Install the new particle filter element
Caution :
Only use original TEKA particle filter elements.
•Raise the lifting mechanism (Pos.16) by turning the locking screw (Pos.17) until the pre-
filter tray (Pos.13) sits tight. (At this time check the sealing gasket under the lid (Pos.7) for
possible damage.
•Close the filter access door (Pos.10).
Connect the filter unit to the mains circuit. (Refer to the data on the type plate)
8 Disposal
To ensure perfect operation of your TEKA - SF-BIA extractor unit and proper disposal of the dust
that has been extracted, we offer the following services:
•Help with finding a waste disposal company in your vicinity.
•On request, we can supply a list of all waste disposal companies in Germany, free of charge.
•A service and maintenance contract.
•A customer help line.
Call our service department for these options: they are at your service – round the clock.
TEKA Fume Extraction LTD.
1 Liverpool Road North
GB-Maghull L31 2 HB
Telephone: ++44-(0) 151-2874775
Fax: ++44-(0) 151-2879601

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9 Technical data
Filter unit CAREMASTER
1x Suction arm
CAREMASTER
2x Suction arm
Supply voltage V 230 / 400 / 500 230 / 400 / 500
Current type Ph 1 / 3 / 3 1 / 3 / 3
Frequency Hz 50
Motor power kW 1,1 2,2
Max. airflow volume m³/h 1270 2150
Max. vacuum Pa 1800 2100
Enclosure type IP 54
ISO class F
Operating voltage V 24
Duty cycle % 100
Width x depth x height mm 665 x 681 x 995 665 x 681 x 1075
Weight, without arm kg 115 120
Filter insert pre filter, particle filter
Filter area of the pre
filter
m² 0,37
Filter area of the particle
filter
m² 11,5
Filter performance % >99
Noise level
(measured as per DIN 45635
T1: in free air
at 1m distance from the
surface of the machine, max.
airflow volume.
dB(A) ca. 72 ca. 74
10 Parts list
Designation: Article no.
pre filter (Pos.14) 10032
particle filter F9 (Pos.15) 10029
particle filter (Pos.15) 10030

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11 Declaration of conformity TEKA-SF-BIA
TEKA
Absaug - und Entsorgungstechnologie GmbH
Industriestraße 13
D - 46342 Velen
Phone.:[phone] Fax:[phone]
e-Mail: [e-mail] Internet: http://www.teka.me
We herewith declare in sole responsibility that the before mentioned product, starting from machine No.:
7500010011001, conforms to the following standards:
Directives on machine building: 2006/42/EG
Electromagnetic compatibility: 2004/108/EG
Directives on printing device: 97/23/EG
Directives on low voltage: 2006/95/EG
Applied harmonised standards:
- DIN EN 349
- DIN EN 983
- DIN EN 12100 Part 1 and Part 2
- DIN EN 60204 Part 1
- DIN EN ISO 13857
-DIN EN ISO 14121
plus further national standards and specifications:
- DIN 45635 Teil 1
- DIN EN ISO 15012 - 1
This declaration will become void if changes are effected to the suction and filter systems which were
not agreed upon in writing by the manufacturer.
Velen, the 29.December 2009