Teka LFE 101 ST1 User manual

Operating instructions
(Translation of the original operating instructions)
LFE 101 ST1
LFE 201 ST1
LFE 301 ST1
TEKA Absaug- und Entsorgungstechnologie GmbH, Millenkamp 9, D-48653 Coesfeld,
Tel.: [phone], E-Mail: [e-mail], 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
2.4. Residual risk 6
3. Safety instructions 7
3.1. Definition of the hazard symbols 7
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
5.2. Electrical connection 10
5.3. Precoating of the filter cartridges 10
5.4. Connecting the compressed air supply 11
5.4.1. Compressed air supply for the cleaning of the filter cartridges 11
6. Operating the system 12
6.1. Explanation of the operating elements 12
6.2. Connection of an external control 13
7. Maintenance 14
7.1. Reset to maintenance state 15
7.2. Cleaning the filter cartridges 15
7.3. Replacing the filter cartridges 16
7.4. Emptying the dust collecting tank 18
7.5. Draining the condensate 20
7.6. Precoating of new filter cartridges 21
7.7. Replacing the particle filter 22
7.8. Replacing the activated carbon / the activated carbon cassette 24
7.8.1. Replacing the activated carbon 24
7.8.2. Replacing the activated carbon cassette 27
7.9. Replacing the cooling air filters of the turbines 28
7.10. Replacing the filter mats for the air outlet grille 28
7.11. Cleaning/replacing the particle sensor 29
7.12. Check/replace the dust filters for underpressure measurement lines 30
8. ATEX operation 31
8.1. ATEX zoning 31
8.2. Sources of ignition 33
8.2.1. Evaluating the risk of ignition in accordance with DIN EN 80079-36 33
9. Dismantling / Disposal 33
10. Diagnostics and troubleshooting 34
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11. List of spare parts 35
12. Technical data 36
13. EC declaration of conformity 37
14. ATEX Annex to the EC declaration of conformity 38
14.1. ATEX devices 38
14.2. ATEX components 38
15. Training protocol 40
16. Maintenance intervals 41
16.1. Usage-related maintenance 41
16.2. General maintenance 42
16.2.1. Visual inspection of the device 42
16.2.2. Visual inspection of the pipelines for dust deposits 43
16.2.3. Visual inspection of the pneumatic pipes 43
16.2.4. Functional test of the device 43
16.2.5. Electrical test of the electrical lines and earthing connections 44
16.2.6. Test of fixing of the mounted unit elements 44
17. Annex A: ATEX conductivity measurement protocol 45
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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
Installation example:
Z.Nr. 14261701
Pos.1
Pos.2
Pos.3
Pos.4
Pos.5
Pos.6
Pos.7
Pos.8
Pos.9
Pos.10
Operating panel of the control
Dust collecting housing
Filter housing
Particle filter housing
Cleaning housing
Activated carbon housing
Turbine housing
Particle filter
Intermediate frame
Activated carbon cassette
Pos.11
Pos.12
Pos.13
Pos.14
Pos.15
Pos.16
Pos.17
Pos.18
Pos.19
Suction nozzle
Exhaust grille
Connection for mains cable
Connection for external control unit
Industrial connector for the optional
gate valve
Connection for compressed air
Drain valve for compressed air
Swivel castor
Connection for Metering device
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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. The activated carbon filter absorbs gases and unpleasant odours. The subsequent
particle filter cleans even fine smokes and dusts. 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 device is intended for commercial use. If the device is made publicly accessible, it must never be
operated unsupervised by authorized personnel, authorized by the operator.
The intended use of the filter unit is the application combined with laser devices and especially the
extraction and filtration of dusts, fumes and gases.
The filter unit can be used to extract explosive dusts with the following characteristic values (for further
information, see the section on “ATEX operation”):
Kst value
<200 bar*m/sec
MIE (minimum ignition energy)
>10 mJ
Combustibility index
≤ 2
Dust group
IIIB
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
gases, hybrid mixtures, glowing or burning substances, gases, water, etc. The device
must not be operated in explosive zones.
Dangers arising from fire.
If the sucked medium is combustible fume or dust, the operator must determine
beforehand which fire protection measures are to be taken.
2.4. Residual risk
CAUTION
Danger due to possible hazardous materials in the exhaust air flow.
Because the unit does not monitor the quality of the air in the exhaust air flow, we
recommend that you always guide the exhaust air flow exiting our unit to areas (e.g. to the
outside into the open air) in which there is no danger to any living being. To do this, it is
necessary to fit a suitable exhaust air line at the filter unit.
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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.
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.
The device is additionally equipped with a particle sensor, which can detect an increase of
the particles (eg due to fire, filter break, ...) within the device. The particle sensor thus
provides a monitoring of the particulate matter, but does not provide 100% protection for the
detection of a fire. When the particle sensor is triggered, the device switches off.
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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.
WARNING
Explosion hazard!
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.
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. Pay attention to uneven grounds
during the transport. Avoid jerky pushing.
Dangers arising from titling or functional impairments at its destination.
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. As soon as the unit
has reached its intended destination, the brakes of the castors must be activated.
WARNING
Explosion hazard!
The installation location for the filter unit must be examined for potential lightning impacts. If
the possibility of these cannot be excluded then the filter unit must be taken into
consideration in the Operator’s lightning protection concept.
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 outside.
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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.
WARNING
Increased risk of explosion when filter unit switched off.
If the filter unit is left switched off while work is performed at the extraction points then dust
may collect at the extraction points. If the dusts in question are potentially explosive then this
increases the risk of explosion. In its risk assessment for the overall system, the Operator
must therefore ensure that
1) the filter unit is switched ON before any dust/fume-generating work is performed,
2) dust/fume-generating work is ceased promptly when the filter unit is switched OFF
either voluntarily or due to a fault message.
The Operator must also note whether shut-off valves are present between the extraction
point and the filter unit. These must be open while the work is being performed.
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).
WARNING
Explosion hazard!
The lines must be kept as short as possible and must be laid to the extraction point in a way
that optimizes the flow in order to prevent any deposits from forming in the lines. TEKA
Absaug und Entsorgungstechnologie GmbH expressly draws your attention to the fact that
extraction lines that have not demonstrably been configured by TEKA are not covered by the
filter unit’s explosion protection documentation. These must be configured for the application
in question.
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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5.2. Electrical connection
WARNING
Explosion hazard!
The conductivity of lines and system parts must be checked in order to prevent static
charges from building up. Leakage resistances < 10^6 Ohm must be ensured.
The Operator must ensure the equipotential bonding of the unit. To do this, use the earthing
point on the back of the unit.
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.
● Connect the mains cable (see chapter 2.1) to the power supply.
5.3. Precoating of the filter cartridges
For a longer service life of the filter cartridges, the new filter cartridges can be pretreated with filter aid.
However, this is not necessary when using nano filter cartridges.
Explosion hazard due to static charging of the filter cartridges. Precoating is only
admissible with slack lime.
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.
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5.4. Connecting the compressed air supply
NOTICE
The compressed air must be dry and oil-free.
According to ISO 8573-1:2010 the compressed air quality must at least meet: [7:4:4]
➔Partikle size: <40µm
➔Pressure dew point: <= +3°C
➔Oil content: <=5mg/m³
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).
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6. Operating the system
WARNING
Increased risk of explosion when filter unit switched off.
If the filter unit is left switched off while work is performed at the extraction points then dust
may collect at the extraction points. If the dusts in question are potentially explosive then this
increases the risk of explosion. In its risk assessment for the overall system, the Operator
must therefore ensure that
1) the filter unit is switched ON before any dust/fume-generating work is performed,
2) dust/fume-generating work is ceased promptly when the filter unit is switched OFF
either voluntarily or due to a fault message.
The Operator must also note whether shut-off valves are present between the extraction
point and the filter unit. These must be open while the work is being performed.
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
ON-OFF-switch
By means of this switch, the device is switched on and off.
When the device is switched off, it is not disconnected from
the power supply.
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6.2. Connection of an external control
There is the possibility to control the unit from extern. For this purpose, a connection is provided on the
unit (see chapter 2.1).
Connection plug type:
Industrial connector
Number of pins:
10
Pin-Nr.
Designation
Explanation
1, 2
Start contact
In order to switch on the filter unit, a contact has to be connected
between pin 1 and pin 2. The unit is switched out when the contact
is opened.
When the follow-up time is activated, the unit switches off
after the preset period of time.
3, 4
External message
“Fault”
Pin serves for the evaluation of an fault indication.
(NO: normaly open)
5, 6
External message
“Operation”
Pin serves for the evaluation of the operational control.
(NO: normaly open)
PE
Protective earthing
Potential equalisation
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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.
WARNING
Explosion hazard due to dust formation.
Avoid whirling up deposited dust during all maintenance work. Keep away possible ignition
sources from the installation at any time. Use suitable tools to clean and to bond dust during
cleaning work. The maintenance personnel must ensure that static discharges are avoided
during work at the unit.
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.
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7.1. Reset to maintenance state
● 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.
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.
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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. Danger of
unintentional automatic cleaning with the unit switched off.
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 using a disposable protective suit when changing the filter cartridges.
For a longer service life of the filter cartridges the new filter cartridges can be pretreated with filter
aid. However, this is not necessary when using nano filter cartridges. If you wish to precoat the
new filter cartridges nevertheless, please refer to the indications in the chapter “Precoating new
filter cartridges". There you can also find a description of the operating method of a filter aid.
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● 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.
● Open the service door of the filter cartridges. Also open the service door of the cleaning
housing. This is only possible by means of a special electrical spanner.
● Slip the disposal bag from bottom to top over the filter cartridge (A).
● Unfasten the 3 thumb screws (B) of the filter cartridge by turning them clockwise.
● Grab the filter cartridge and turn it a little clockwise to disconnect it from the screw fastening.
Therefore do not touch the filter cartridge directly with your hands, but grab it from the outside
through the bag.
● 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 new filter cartridge into the screw fastening and turn it anticlockwise to the hilt.
Only use TEKA spare filters. Otherwise the proper functioning of the unit is
not guaranteed.
● Hand-tight screw the 3 thumb screws.
● Carry out this procedure for all filter cartridges.
● Close the service door.
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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! Danger of
unintentional automatic cleaning with the unit switched off.
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.
WARNING
Explosion hazard!
During the discharge process, there must not be any effective
sources of ignition in the vicinity of the dust collecting container. The
maintenance personnel must ensure that static discharges are
avoided during work at the unit.
Explosion hazard!
No bags may be placed in the dust collecting container (risk of
build-up of static charges).
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● Open the service door of the dust collecting housing (see chapter 2.1).
● Release the two earth connections.
● Resolve the clamping lever (B) of the dust collecting tank (A).
● Carefully pull the dust collecting tank out of the housing.
● Empty the dust collecting tank into an appropriate, closable container or bag. Dispose of or
store the dust according to the regulations.
● Push the dust collecting tank back into the dust collecting housing.
● Manipulate the clamping lever so that the dust collection container is pressed tightly against the
above housing.
● Re-establish the two earth connections.
There is a risk of explosion during operation if an earth connection is not
attached.
● Close the service door.
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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.
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