Teka Filtercube 2-IFA User manual


Operating instructions
(Translation of the original operating instructions)
Filtercube 2 - IFA
TEKA Absaug- und Entsorgungstechnologie GmbH, Industriestraße 13, D-46342 Velen,
Tel.: [phone], E-Mail: info@teka.eu, www.teka.eu
1

Table of contents
1 General 4
2 Description of the system elements 5
2.1 Illustration of the system elements 5
2.2 Functionality of the system 6
2.3 Intended use 6
3 Safety instructions 6
3.1 Definition of the hazard symbols 6
3.2 General safety instructions 7
4 Storage, transport and installation of the device 8
5 Commissioning 9
5.1 Connecting the suction line and exhaust air line 9
5.1.1 Assembly of the silencing housing 10
5.2 Electrical connection 11
5.3 Precoating of the filter cartridges 12
5.4 Connecting the compressed air supply 12
5.4.1 Compressed air supply for the cleaning of the filter cartridges 12
6 Operating the system 13
6.1 Explanation of the operating elements 13
7 Maintenance 14
7.1 Reset to maintenance state 15
7.2 Cleaning the filter cartridges 16
7.3 Replacing the filter cartridges 17
7.4 Emptying the dust collecting tank 19
7.5 Draining the condensate 20
7.6 Precoating of new filter cartridges 21
7.6.1 Feeding the precoat via a FVS (TEKA spark pre-separator) 22
7.7 Cleaning the copper baffle plate 23
8 Dismantling / Disposal 24
BA_Filtercube_2_IFA_171120_EN
2
20.11.2017

9 Diagnostics and troubleshooting 24
10 List of spare parts 26
11 Technical data 27
12 EC declaration of conformity 28
13 Training protocol 29
14 Maintenance intervals 30
14.1 Usage-related maintenance 30
14.2 General maintenance 30
14.2.1 Visual inspection of the device 31
14.2.2 Visual inspection of the pipelines for dust deposits 31
14.2.3 Visual inspection of the pneumatic pipes 32
14.2.4 Functional test of the device 32
14.2.5 Electrical test of the electrical lines and earthing connections 33
BA_Filtercube_2_IFA_171120_EN
3
20.11.2017

1 General
Congratulations on purchasing the product from TEKA.
Our engineers ensure that our devices reflect the state of the art through continuous development.
Nevertheless, misuse or misconduct can endanger your safety. Please observe the following for a
successful use of the device:
Only authorised and instructed personnel can carry out transport, operation,
maintenance and repair of the device. The operator must ensure that the operating
personnel take note of these instructions.
Please read these instructions before operating the device, and observe the safety
precautions to avoid injury!
Store this manual in a safe place! These instructions are to be regarded as a component
of the product!
Adhere to all product notes!
Modifications or conversions that the operator carries out at the device without the
consent of the manufacturer, can lead to new safety hazards or to the loss of warranty
claims.
Observe the manufacturer’s instructions. Contact the manufacturer in case of any
uncertainty:
Tel: [phone]
E-mail: [email protected]
BA_Filtercube_2_IFA_171120_EN
4
20.11.2017

2 Description of the system elements
2.1 Illustration of the system elements
Z.Nr. 04523702
Pos.1
Pos.2
Pos.3
Pos.4
Pos.5
Dust collecting housing
Filter housing
Cleaning housing
Fan housing
Silencing housing
Pos.6
Pos.7
Pos.8
Pos.9
Suction nozzle
Exhaust grille
Connection for compressed air
Drain valve for compressed air
BA_Filtercube_2_IFA_171120_EN
5
20.11.2017

2.2 Functionality of the system
The filter unit serves to suck off and filter polluted air (according to the intended use). The air is purified
on the surface of the filter cartridge in the filter section of the unit. The separated dust is collected in a
dust collecting tank. An automatic filter monitoring indicates when a cleaning or a replacement of the
filters is necessary. The purified air is led back into the working room via an exhaust air grille.
2.3 Intended use
The filter unit is intended for extraction and filtration of dusts and fumes that result from thermal joining
and cutting of metals. The filter unit is amongst others suitable for separating welding smokes of
unalloyed and alloyed steels as well as of high-alloy chromium-nickel steels and therefore meets the
highest welding fume separation category “W3” according to DIN EN ISO 15012-1.
WARNING
Improper use can damage parts and be a danger to life and limb!
The device must not be used for the extraction of oil-laden welding fume, explosive dust and
gases, hybrid mixtures, glowing or burning substances, gases, water, etc. The device must
not be operated in explosive zones.
3 Safety instructions
3.1 Definition of the hazard symbols
The device is constructed according to the state of the art and the recognised safety regulations.
Nevertheless, during use threats to life and limb of the user or other persons may arise. The impairment
of the machine or other property are also possible. In these instructions we warn by using corresponding
indications.
WARNING
WARNING
These instructions are made in case of risks that can lead to injury or death.
CAUTION
CAUTION
These instructions are made in case of risks that can lead to injury.
NOTICE
NOTICE
These instructions are made in case of risks that can lead to material damages.
Information notes are no hazard warnings; they call attention to useful information.
BA_Filtercube_2_IFA_171120_EN
6
20.11.2017

3.2 General safety instructions
WARNING
Dangers arising from improper use / unauthorised operations.
The operator must ensure that their authorised personnel are familiar with all the safety
indications in this manual in advance. The operator is responsible for ensuring that all work
is carried out by authorised and qualified personnel. We therefore recommend using the
training protocol on the last page for that purpose (see chapter “Training protocol”).
Laymen are allowed to operate the device after having received the necessary instructions.
But they are not allowed to carry out any installation, repair or maintenance work.
Dangers arising from fire.
In case of fire, if possible, switch the unit immediately off or disconnect it from the power
supply. Fire extinguishing measures which the operator is obliged to determine beforehand
must be initiated immediately.
WARNING
Dangers arising from electricity.
The operator must ensure that electrical plants and equipment are only built, modified and
maintained by a qualified electrician or under the direction and supervision of a qualified
electrician. Do not work on components if you are not sure that these are disconnected. If
necessary, disconnect the device from the electric power supply and secure it against
unauthorized restarting.
BA_Filtercube_2_IFA_171120_EN
7
20.11.2017

4 Storage, transport and installation of the device
WARNING
Risk of injury from tilting or unmounted components when stored or transported.
The device must be secured against tilting and slipping when it is stored or transported. Do
not stand under or next to the floating load. Lift trucks, forklift trucks and transport cranes
must have a sufficient minimum load bearing capacity.
Dangers arising from titling or functional impairments at its destination.
The unit may only be set up on a suitable surface. The unit may only be set up on a suitable
surface. The surface must be vibration-free and horizontal. The operator must check the
bearing capacity of the surface. The unit must be secured on the surface, for example using
lag bolts or heavy-duty anchors.
NOTICE
Damage or functional impairment of the unit due to climatic influences.
The unit must be stored in a dry place and protected against moisture during transport. As a
matter of principle, the filter unit is not designed to be installed outdoors. In this case contact
the manufacturer in order to find out if a caping or a trace heating system are necessary.
● First the filter unit as delivered must be transported to its destination.There the filter unit must be
moved to an upright position.Therefore, lift the filter unit with lifting tools.Use the 4 lifting rings
(A).
Use appropriate lifting tools (forklift truck, transport crane,...) with a
minimum load-carrying capacity of 500 kg. The filter unit must be secured against tilting
and slipping when it is moved, lifted or put down. No one is allowed to stand under or
beside the load. Use only appropriate ladder tools.
● Then the filter unit must be set up and fixed on a suitable surface at its exact intended
destination. Use the forklift truck skids (B) to transport the filter unit there.
BA_Filtercube_2_IFA_171120_EN
8
20.11.2017

5 Commissioning
WARNING
Dangers arising from a defective condition of the unit.
Make sure that the measures described in this chapter are completed before the
commissioning of the unit. All doors of the unit must be closed and all necessary connections
must be attached before turning the unit on. Do not operate the unit if any components are
defective, missing or damaged. Check the orderly condition of the unit before switching it on.
The unit must not be operated without a filter element.
NOTICE
Damaged supply lines.
Make sure that the supply lines are protected against damage by forklift trucks and similar
events. Protect all supply lines from heat, moisture, oil and sharp edges.
5.1 Connecting the suction line and exhaust air line
For extracting the contaminated air, a suction line must be connected to the suction nozzle (see chapter
2.1).
CAUTION
Danger for the respiratory tract arising from polluted ambient air. Dust deposits in the
suction pipe are possible.
Only operate the system if the necessary suction line is fitted. The suction line must be
dimensioned according to the application. If this has not already been carried out by TEKA, a
suitably qualified employee must be consulted. If the suction line includes extraction
elements (e.g. suction arms, pipe grills, etc.), these must also be included in the layout.
Depending on the application, the suction pipe must be equipped with extraction elements (suction arm,
extraction hose, round duct grille, etc.). When using a capture element with an extractor cowl, the
extractor cowl must follow the weld seam, if possible by using the movement of the welding fume
caused be thermal influences.
You have to make sure that connections between the workpiece and the suction
hood (and in general between the workpiece and the filter unit) are avoided in order to prevent
the welding current from flowing back to the welding machine via the protective conductor of the
filter unit.
If the air shall be directly sucked off by an upstream machine, the suction line must be connected to the
capture opening of the upstream machine.
The purified air is led back into the working environment via the exhaust air grille (see chapter 2.1)
(recirculation mode). If it is desired to lead the purified air out of the working environment, an exhaust air
pipe must be attached at the discharge grille.
BA_Filtercube_2_IFA_171120_EN
9
20.11.2017

5.1.1 Assembly of the silencing housing
The silencing housing (see chapter 2.1) is supplied unassembled and must be assembled to the fan
housing.
● Screw the two supplied flat-head screws DIN 923 M6x16 (B) into the matching threads.
● The silencing housing (A) is hung up on top on the two flat-head screws (B).
● With the help of the four toggle lever closures (C + D) the silencing housing is then mounted to
the fan housing.
● In a final step the two upper toggle lever closures (C) are secured with the help of the two
supplied split pins (E). The split pins are then widened at the bottom.
BA_Filtercube_2_IFA_171120_EN
10
20.11.2017

5.2 Electrical connection
WARNING
Risk of electric shock.
Electrical plants and equipment may only be built, modified and maintained by a qualified
electrician or under the direction and supervision of a qualified electrician. Do not work on
live electrical components and elements if you are not sure that these are indeed
disconnected. If necessary, disconnect the device from the mains. The operator is
responsible for a potential-free balance of the equipment.
If the unit is equipped with a frequency converter, then it may only be operated on networks
with an AC/DC sensitive RCCB. For frequency converter operation, the cross section of the
protective conductor
● must be at least 10mm²,
● and must be at least equal to the size of the operator side outer conductor
cross-section.
CAUTION
Health hazard arising from unintentional cleaning processes.
Switch on the control only if the unit is in operational condition.
NOTICE
Electric malfunction possible in cause of an incorrect power supply.
Pay attention to the admissible supply voltage. Please observe the specifications on the type
plate.
● Mount the housing of the external control (if it is not mounted on the device itself) close to the
device on the wall or at any other appropriate mounting point. Or mount the control together
with a cabinet console on a suitable surface, for example using lag bolts or heavy-duty anchors.
The housing is not suited for outdoor installation.
● Connect all visible cables and hoses are according to their functions. When delivered they are
labelled according to their functions. When connecting to the control, please observe the
specifications on the circuit diagram which is attached to the control.
● Connect the unit to the power supply.
● Check if the direction of fan rotation is correct. A wrong rotation direction can be identified
thanks to the sticker sticked to the fan scroll which is showing the direction. Compare the
rotation direction on the sticker to the rotation direction of the motor cooling fan when the motor
is running down after being switched off. If the motor rotates in the wrong direction, disconnect
the device from the power supply and exchange two phases at the supply line to the control.
When the fan rotates in the wrong direction, the extraction capacity is
reduced.
BA_Filtercube_2_IFA_171120_EN
11
20.11.2017

5.3 Precoating of the filter cartridges
For a longer service life of the filter cartridges they are pretreated with a filter aid (precoat) in the factory.
When the operator orders and installs new filter cartridges, we recommend to also precoat them before
the commissioning.
Please read and refer to "Precoating new filter cartridges" in the chapter "Maintenance". There
you can also find a description of the operating method of the precoat.
5.4 Connecting the compressed air supply
5.4.1 Compressed air supply for the cleaning of the filter cartridges
The filter cartridges of the system are automatically cleaned. Cleaning is carried out pneumatically via a
built-in compressed air tank.
Without compressed air supply the filter cartridges will become dirty very quickly.
● The external compressed air supply must be assured with an approved compressed air hose.
For the connection to the device, the compressed air hose must be equipped with a quick
coupling for an insert sleeve DN 7.2.
The compressed air must be dry and oil-free.
● The operating pressure of the compressed air supply must be a minimum of 3 bars and
maximum of 4 bars.
In case of the pressure being too low, the compressed air tank does not reach
quickly enough the operating pressure for the following cleaning. There is a risk of
material damage when the pressure is too high.
● Connect the compressed air hose to the insert sleeve (see chapter 2.1).
BA_Filtercube_2_IFA_171120_EN
12
20.11.2017

6 Operating the system
6.1 Explanation of the operating elements
Control functions, setting options for programs, menu navigation, error messages, etc. are
described in the enclosed operating manual of the unit control. There is also an explanation of the
elements of the control panel.
Operating elements for the device control
Representa
tion
Designation
Description / function
Main switch
●OFF: The device is disconnected from the power supply.
●ON: The device is connected to the power supply and
ready to operate.
The main switch also serves as an emergency
off switch.
only at device Filtercube 2H (resp. Filtercube 2
with external steering)
Operating elements for status and error messages
Representa
tion
Designation
Description / function
Stroboscope flash
The stroboscope flash draws attention to an error message of
the device control by flashing up. The error message is shown
on the display of the control.
BA_Filtercube_2_IFA_171120_EN
13
20.11.2017

7 Maintenance
In accordance with national regulations, the operator is obliged to carry out repeat and functional tests.
Unless otherwise specified by national regulations, we recommend regular visual inspections and
functional tests of the device as described in the chapter “Maintenance intervals”.
You find the chapter “Maintenance intervals” at the end of the document. The general
maintenance (visual inspection, etc.) is also explained there.
In the chapter “Maintenance intervals” there is information on the maintenance intervals of the filter
elements. But these are only recommendations. Depending on the application (multi-shift operation,
dust generation, ...) it may be necessary for the operator to change the maintenance intervals.
In this chapter the maintenance work which is caused by wear caused during operation is described.
WARNING
Work on the open system entails the risk of electrical shock or accidental restart the
system. Both pose a danger to life and limb.
When cleaning and servicing equipment during the replacement of parts or when changing
to another function, set the device to maintenance condition first (see chapter “Reset to
maintenance state”).
A recommissioning of the device must only occur if it is ensured that the device is
functionally equivalent to the original state.
CAUTION
Hazards to the respiratory tracts are possible.
All maintenance work must only be carried out in well-ventilated rooms and
while wearing an appropriate respiratory mask! We recommend: respiratory
protection half mask DIN EN 141/143 protection level P3. For all maintenance
work ensure a cautious handling of filter elements and components in order to
avoid whirling up dust.
The operator is obliged to store and dispose of the collected dust in accordance with national or
regional regulations. For all maintenance or cleaning work please refer to the applying
environmental regulations. Pollutants and filter elements must be disposed of or stored according
to the regulations as well. If you have any doubts, we recommend contacting a disposal
contractor in your area.
BA_Filtercube_2_IFA_171120_EN
14
20.11.2017

7.1 Reset to maintenance state
Filtercube 2H (resp. Filtercube 2 with external steering):
● Switch off the unit. Then disconnect the unit from the power supply by setting the main switch in
the “OFF” position. Secure the unit against unauthorized restarting during maintenance.
● Disconnect the compressed air hose of the external compressed air supply from the insert
sleeve (see chapter 2.1).
● Empty the compressed air tank by opening the drain valve (see chapter 2.1) with a suitable
screwdriver. Minor quantities of condensation water can leak out when opening the drain valve.
Close the drain valve when the compressed air tank is entirely empty.
When opening the drain valve a compressed air blast can occur!
● After completion of all maintenance work the unit can be reconnected to the power supply and
the external compressed air supply.
Filtercube 2N:
● Switch off the unit. Unplug the mains plug. Secure the unit against unauthorized restarting
during maintenance.
● Disconnect the compressed air hose of the external compressed air supply from the insert
sleeve (see chapter 2.1).
● Empty the compressed air tank by opening the drain valve (see chapter 2.1) with a suitable
screwdriver. Minor quantities of condensation water can leak out when opening the drain valve.
Close the drain valve when the compressed air tank is entirely empty.
When opening the drain valve a jet of compressed air can occur.
● After completion of all maintenance work the unit can be reconnected to the power supply and
the external compressed air supply.
BA_Filtercube_2_IFA_171120_EN
15
20.11.2017

7.2 Cleaning the filter cartridges
CAUTION
A sudden jet of compressed air and huge amounts of whirled up dust are possible
due to an automatic cleaning with an opened service door.
During the operation of the device, the service door of the filter housing must not be opened.
The same applies to the ready to operate condition (standby) as there is also the possibility
of an automatic cleaning (subsequent cleaning).
The filter cartridges are reusable filters and can be cleaned. The cleaning of the filter cartridges is
automatically carried out.
The degree of pollution of the filter cartridges is electronically monitored. In order to assure the required
extraction capacity of the device, the cleaning of the filter cartridges starts automatically when a preset
differential pressure value is reached. If the preset differential pressure value is not undercut after the
cleaning of the filter cartridges, another cleaning starts. The filter unit remains in operation during the
automatic cleaning. The compressed air blast is produced in opposite direction to the intake. The
cleaned dust falls downwards in the dust collecting tank.
Depending on the setting of the control unit there can be automatic postcleanings of the filter cartridges
even when the unit is switched off.
When the maximal admissible differential pressure value is reached, the device triggers an alarm (see
chapter “description of the control elements”). If despite of the automatic cleaning of the filter cartridge
the alarm value is not undercut anymore, the filter cartridge must be replaced. (see chapter: “Replacing
the filter cartridges”).
The differential pressure values in the control unit that initiate a cleaning or a filter alarm are preset
values adapted to the filter unit. Please find detailed information concerning the functioning in the
enclosed operating instructions of the control unit.
When using optional extraction elements with a suction hood, their throttle valve must be closed as soon
as the device is switched off. Otherwise dust can escape from the suction hood in case of possible
automatic subsequent cleanings.
BA_Filtercube_2_IFA_171120_EN
16
20.11.2017

7.3 Replacing the filter cartridges
Replacing the filter cartridges becomes necessary when the filter cartridges are saturated with dirt in a
manner that despite of the cleaning the filter alarm is triggered again at very short intervals or
permanently. (The filter alarm is described in chapter “Cleaning the filter cartridges”.)
CAUTION
Whirling up dust is possible due to the polluted filter cartridges.
The filter cartridges must be cleaned before being replaced. This is done by carrying out 3
manual cleanings via the unit control (see separate operating instructions). The filter unit
must be switched off beforehand but without disconnecting the unit from the power supply.
After the cleaning, disconnect the filter unit from the power supply and secure it against
being switched on again. After cleaning the filter cartridges wait about 5 minutes before
opening the service door of the filter housing.
We recommend to pretreat new filter cartridges with filter aid (e.g. precoat) before the first
commissioning. Refer to the chapter "Precoating new filter cartridges".
● The changing of the filter cartridges must be carried out by two people.
● Before changing the filter cartridges hold ready an appropriate container (e.g. PE bag) for
disposal.
The polluted filter cartridges must be packed into an appropriate container
(e.g. PE bag). PE bags are optionally available (see list of spare parts)! We recommend
having disposal bags in stock.
BA_Filtercube_2_IFA_171120_EN
17
20.11.2017

● Open the service door of the filter cartridges by opening the door handles. To do this, the door
handle, which is equipped with a lock, must be unlocked using a double-bit key.
● Resolve the clamping screw (pos. A) of the cartridge holder (pos. B) and slip the disposal bag
over the cartridge holder and the filter cartridge (pos. C).
● Hook off the cartridge holder from the cartridge guiding (pos. E) and take it out of the device
together with the filter cartridge and the disposal bag.
● Loosen the cylinder nut (pos. F) outside on the cartridge's bottom. Therefore do not touch the
cylinder nut directly with your hands, but grab it from the outside through the bag.
● Pull the cartridge holder out of the disposal bag past the filter cartridge without generating dust.
Take the displacer (pos. D) out of the filter cartridge without generating dust.
● Carefully close the disposal bag (e.g. with a cable fastener) and store or dispose of it together
with the polluted filter cartridge in an appropriate container according to the regulations.
● Insert the displacer into the new filter cartridge in a way that the screw of the displacer is put
through the hole of the cartridge's bottom. Fasten the displacer with the cylinder screw nut from
the outside.
Check whether the seal is against the thread of the displacer and whether it is
undamaged. Otherwise, a replacement seal must be used (see list of spare parts).
● Push the new filter cartridge into the cartridge holder.
Only use TEKA spare filters. Otherwise the proper functioning of the unit is
not guaranteed.
● Fasten the clamping screw of the cartridge holder.
● Close the service door by closing the door handles. Also the door handle, which is equipped
with a lock, must be locked again.
BA_Filtercube_2_IFA_171120_EN
18
20.11.2017

7.4 Emptying the dust collecting tank
The dust collection container must be cleaned after a certain number of operating hours. This range
depends on the amount of dust. The dust collecting tank may only be filled up to a maximum of 25%.
The filling level has to be proofed at least once a week.
CAUTION
Whirling up dust is possible due to the polluted filter cartridges!
The filter cartridges must be cleaned before emptying the dust collecting tank.This is done
by carrying out 3 manual cleanings via the unit control (see separate operating
instructions).The filter unit must be switched off beforehand but without disconnecting the
unit from the power supply.After the cleaning, disconnect the filter unit from the power supply
and secure it against being switched on again.After cleaning the filter cartridges wait about 5
minutes before opening the service door.
Before emptying the dust collecting tank hold ready an appropriate container (e.g. PE bag). The
bags are optionally available at TEKA, see list of spare parts. We recommend having PE bags in
stock.
● Open the service door of the dust collecting housing (see chapter 2.1).
● Lower the lifting device (B) by turning the clamping screw (C). Therefore, use the hexagon key
that is located on the right of the clamping screw.
● Carefully pull the dust collecting tank (A) out of the housing.
● Close the dust collection bag (e.g. with a cable fastener).
● Remove the dust collection bag and store or dispose of it according to the regulations.
● Place a new dust collection bag in the dust collection container so that the bag is put over the
edge of the dust collection container.
● Push the dust collecting tank back into the dust collecting housing.
● Elevate the lifting device by turning the clamping screw so that the dust collection container is
pressed tightly against the above housing.
● Close the service door.
BA_Filtercube_2_IFA_171120_EN
19
20.11.2017

7.5 Draining the condensate
Operation with compressed air can result in condensation water being gradually deposited in the
compressed air tank. The condensed water must be emptied regularly. The maintenance interval
depends heavily on the quality of the compressed air and cannot, therefore, be determined in advance.
CAUTION
When opening the drain valve a blast of compressed air is possible.
Open the drain valve slowly.
● Empty the compressed air tank by opening the drain valve (see chapter 2.1) with a suitable
screwdriver. Let the escaping condensate flow into a suitable container.
● Close the drain valve.
BA_Filtercube_2_IFA_171120_EN
20
20.11.2017