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
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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
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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
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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]
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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
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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.
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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.
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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.
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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.
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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.
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