Teka LFE 101 User manual

Operating instructions
(Translation of the original operating instructions)
LFE 101
LFE 201
LFE 301
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
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 9
5.3. Precoating of the filter cartridges 10
5.4. Connecting the compressed air supply 10
5.4.1. Compressed air supply for the cleaning of the filter cartridges 10
6. Operating the system 11
6.1. Explanation of the operating elements 11
6.2. Connection of an external control 11
7. Maintenance 12
7.1. Reset to maintenance state 13
7.2. Cleaning the filter cartridges 13
7.3. Replacing the filter cartridges 14
7.4. Emptying the dust collecting tank 16
7.5. Draining the condensate 17
7.6. Precoating of new filter cartridges 18
7.7. Replacing the particle filter 19
7.8. Replacing the activated carbon / the activated carbon cassette 20
7.8.1. Replacing the activated carbon 20
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7.8.2. Replacing the activated carbon cassette 22
7.9. Replacing the cooling air filters of the turbines 23
7.10. Replacing the filter mats for the air outlet grille 23
7.11. Cleaning/replacing the particle sensor 24
8. Dismantling / Disposal 25
9. Diagnostics and troubleshooting 25
10. List of spare parts 27
11. Technical data 28
12. EC declaration of conformity 29
13. Training protocol 30
14. Maintenance intervals 31
14.1. Usage-related maintenance 31
14.2. General maintenance 32
14.2.1. Visual inspection of the device 33
14.2.2. Visual inspection of the pipelines for dust deposits 33
14.2.3. Visual inspection of the pneumatic pipes 34
14.2.4. Functional test of the device 34
14.2.5. Electrical test of the electrical lines and earthing connections 35
14.2.6. Test of fixing of the mounted unit elements 35
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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
Harting connection for the optional
gate valve
Connection for compressed air
Drain valve for compressed air
Swivel castor
Connection for Metering device for
precoat
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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.
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.
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.
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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.
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.
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.
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).
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.
5.2. Electrical connection
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.
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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
(e.g. precoat). However, this is not necessary when using nano filter cartridges.
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
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
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.
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:
“Harting”
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.
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.
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.
For a longer service life of the filter cartridges the new filter cartridges can be pretreated with filter
aid (e.g. precoat). 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.
● 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.
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● 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.
● Remove the filter frame (C) in a dust-free manner from inside the filter cartridge.
● 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 filter frame into the new filter cartridge.
Only use TEKA spare filters. Otherwise the proper functioning of the unit is
not guaranteed.
● Insert the new filter cartridge into the screw fastening and turn it anticlockwise to the hilt.
● 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!
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.
● Open the service door of the dust collecting housing (see chapter 2.1).
● 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.
● 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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7.6. Precoating of new filter cartridges
Before the first commissioning new filter cartridges can be pre-treat with precoat consumable. The
precoat consumable assists against a "caking" of extracted particles on the filter surface and thus
prolongs the life of the new filter cartridge
Unlike with other maintenance work, this step must be carried out with the system switched on and
operating. This is necessary to allow the filter aid to disperse on the surface of the filter cartridges
through suction.
CAUTION
On contact the precoat consumable can be hazardous to the
respiratory tract and cause skin irritation or eye irritation.
Observe the listed manufacturer instructions provided:
Handling: Avoid the formation of dust!
Storage: Seal the container tightly before storage!
Respiratory protect: Dust mask without protection level!
Hand protection: Protective gloves in cloth, rubber or leather!
Eye protection: Safety glasses with side shields!
Body protection: Anti-static work shoes!
CAUTION
During operation of the device an automatic cleaning can take place. This involves the
risk of a sudden jet of high-pressure air and excessive dust formation at the point of
entry of the filter aid.
At first make sure that there is no compressed air in the compressed air tank. Please refer to
the chapter "Reset to factory settings". Before switching the device back on, disconnect the
compressed air hose from the device.
● Provide sufficient filter aid. We recommend using 10 grams for each square metre of the filter
surface. The filter aid is available at TEKA (see list of spare parts).
● Choose the capture point in the suction pipe that is the closest to the filter cartridges. E.g. an
inspection flap can be used as a capture point.
● Switch the device on.
● Let the filter aid bit by bit be sucked in via the capture point.
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7.7. Replacing the particle filter
Replacing the particle filter is necessary when the device control signals the corresponding error. (see
chapter "Description of the control elements").
CAUTION
Whirling up dust is possible.
The particle filter is a disposable filter element. Do not try to clean the filter element.
The particle filter has the function of a police filter. This means that the filter is located behind the
other filter elements according to the air flow direction. The police filter ensures that only clean air
from the filter system flows back into the environment, even if one of the other filter elements is
defective. The filter unit switches off when the police filter is saturated and can not be operated as
long as the error message persists.
● Open the service door of the particle filter housing (see chapter 2.1).
● Lower the lifting device (A) by turning the clamping screw (B).
● Carefully pull the entire filter pack, incl. the particle filter (see chapter 2.1) out of the housing.
Before doing so the projecting measuring hose has to be separated from the intermediate
frame.
● Replace the particle filter.
Only use TEKA spare filters. Otherwise the proper functioning of the unit is
not guaranteed.
● Push the filter pack back into the filter housing. Make sure that the filter elements are inserted in
the correct order. Then reconnect the measuring hose at the intermediate frame.
The seals of the particle filter, the activated carbon cassette and the
intermediate frame must always be on the top.
● Elevate the lifting device by turning the clamping screw so that the upper filter element is
pressed tightly against the above housing.
● Close the service door.
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7.8. Replacing the activated carbon / the activated carbon cassette
The activated carbon absorbs gases and unpleasant odours. The activated carbon has to be replaced
as soon as gases appear on the clean air side.
Therefore, replace the activated carbon in the activated carbon cassette. Alternatively, you can replace
the entire activated carbon cassette. Different spare parts are required for these two options (see list of
spare parts).
The saturation degree of the activated carbon is not monitored.
7.8.1. Replacing the activated carbon
● Open the service door of the
activated carbon housing (see
chapter 2.1).
● Lower the lifting device (A) by
turning the clamping screw (B).
● Carefully pull the entire filter pack,
incl. the activated carbon cassette
(see chapter 2.1), out of the
housing. Before doing so the
projecting measuring hose has to
be separated from the
intermediate frame.
● Remove the cover of the activated
carbon cassette. To do this, it is
necessary to undo the screws.
(The activated carbon cassette shown
in the illustration may possibly be of a
different size to the one installed in
your filter unit. However, the principle
is identical.)
● Remove the top filter fleece mat.
● Carefully empty the activated
carbon. The used activated carbon
must be emptied into an
appropriate container and
disposed of.
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