Teka DusToo User manual

Operating instructions
(Translation of the original operating instructions)
DusToo
TEKA Absaug- und Entsorgungstechnologie GmbH, Millenkamp 9, D-48653 Coesfeld,
Tel.: [phone], E-Mail: [e-mail], 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 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 an extraction element 9
5.2. Electrical connection 9
5.3. Connecting the compressed air supply 10
5.3.1. 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. Setting the automatic filter cartridge cleaning 12
7. Maintenance 13
7.1. Reset to maintenance state 14
7.2. Cleaning the filter cartridges 14
7.3. Replacing the filter cartridges 15
7.4. Emptying the dust collecting tank 16
7.5. Replacing the carbon brushes 16
8. Dismantling / Disposal 17
9. Diagnostics and troubleshooting 18
10. List of spare parts 18
11. Technical data 19
12. EC declaration of conformity 20
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13. Training protocol 21
14. Maintenance intervals 22
14.1. Usage-related maintenance 22
14.2. General maintenance 22
14.2.1. Visual inspection of the device 23
14.2.2. Functional test of the device 23
14.2.3. Electrical test of the electrical lines and earthing connections 24
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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. 12473703
Pos.1
Pos.2
Pos.3
Pos.4
Pos.5
Pos.6
Pos.7
Filter housing
Cleaning housing
Turbine housing
Cover plate
Suction nozzle
Exhaust grille
Connection for mains cable
Pos.8
Pos.9
Pos.10
Pos.11
Pos.12
Clock generator
Connection for compressed air
Swivel castor
Dust collecting tank
Toggle lever
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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 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 filter unit is mainly used to extract and filter dust and fumes.
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.
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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 an extraction element
For extracting the contaminated air - according to the intended use - the provided extraction element
(e.g. suction arm, suction hose, ...) must be connected at the suction nozzle (see chapter 2.1).
If one extraction hose is used, the supplied cap must be mounted on the unused intake nozzle.
Otherwise, false air would be sucked in through this intake nozzle and the extraction capacity would be
unnecessarily reduced.
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.
● Reconnect the mains cable (see chapter 2.1) to the power supply.
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5.3. 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
5.3.1. 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
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.
Potentiometer
The potentiometer can be used to set the speed and
thus the air volume flow.
Operating elements for status and error messages
Representa
tion
Designation
Description / function
Signal lamp “red”
Flashing up means that the air-flow rate of the device is not
sufficient anymore. Filter elements must be cleaned or
replaced.
When using extraction elements with a suction hood, it is
possible that the throttle valve(s) in the suction hood are
closed. In this case open the throttle valves.
Indicator lamp “green”
Flashing up means that the device is in operation.
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6.2. Setting the automatic filter cartridge cleaning
The filter cartridge is cleaned automatically by means of the pulse generator (see chapter 2.1). For this
purpose, a pneumatic cleaning is triggered after a preset time interval. The opening time controls the
duration of the valve cleaning. The factory-set values can be changed if required:
●Time interval: adjustable via controller "B”.
●Opening time: adjustable via controller "A”.
●Manual cleaning: pressing button "C" manually triggers a cleaning.
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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
● 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 pressing the "TEST" button of the pulse generator three
times in a row.
● Switch off the unit. Unplug the mains plug. Secure the unit against unauthorized restarting
during maintenance.
● 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
The filter cartridges are reusable filters and can be cleaned. The cleaning of the filter cartridges is
automatically carried out, according to a preset time interval.
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.
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”).
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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 a
manual cleaning three times. A manual cleaning is carried out by pressing the "TEST" button
of the pulse generator. After the cleaning, disconnect the filter unit from the power supply
and secure it against being switched on again.
● 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).
● Open the toggle levers (see chapter 2.1). This allows the housing parts to be separated from
each other.
● Loosen the 6 screws (A) on the top of the filter housing. Pull the filter cartridge downwards out
of the filter housing.
● Insert the new filter cartridge and screw it in place.
Only use TEKA spare filters. Otherwise the proper functioning of the unit is
not guaranteed.
● Put the housing parts back on top of each other. Reconnect the housing parts by means of the
toggle levers.
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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 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 a manual cleaning three times. A manual cleaning is carried out by pressing
the "TEST" button of the pulse generator. After the cleaning, disconnect the filter unit from
the power supply and secure it against being switched on again.
● Open the lower toggle levers (see chapter 2.1). This allows the upper housing parts to be
separated from the dust collecting tank.
● Carefully empty the dust from the dust collecting tank. Dispose of or store the dust according to
the regulations.
● Put the housing parts back on top of each other. Reconnect the housing parts by means of the
toggle levers.
7.5. Replacing the carbon brushes
The turbine must be checked after every 300 operating hours on carbon brushes which must be
replaced if necessary. Please consider that replacement interval of the carbon brushes can vary. When
turning on and off the unit frequently the collector of the turbine wears out differently what consequently
has an influence on change interval of the carbon brushes. The turbine is subject to abrasive wear as
well. Its average life span is about 600-800 operating hours.
● Remove the cover plate (see chapter 2.1).
● Pull the blade receptacle of the mains line out of the blade terminal of the carbon brush.
● Press the barb of the carbon brush down and withdraw the carbon brush.
● Insert the new carbon brush until the barb locks into place.
● Put the blade receptacle of the mains supply on the blade terminal of the new carbon brush.
● Mount the cover plate.
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8. Dismantling / Disposal
Only authorised personnel may disassemble the machine.
WARNING
Dangers arising from electricity.
Before the dismantling of the machine it has to be disconnected from the power supply and
all supply lines.
CAUTION
Whirling up dust is possible due to the deposited dust.
During all work a suitable respiratory protection and protective clothing have to
be worn.
The operator is obliged to store and dispose of the collected dust in accordance with national or
regional regulations.
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9. Diagnostics and troubleshooting
A list of possible system errors is provided in the table.
Faults indicated by control elements are explained in the chapter “Description of the control
elements”.
A recommissioning of the device must only occur if it is ensured that the system is functionally
equivalent to the original state. Repairs may only be carried out by TEKA personnel or, after
consultation with TEKA GmbH, by the personnel authorised by the operator.
Adhere to the instructions in the chapter "Safety instructions" and " Maintenance" when carrying out any
repairs. If in doubt, contact our TEKA service department:
Tel: [phone]
E-mail: [email protected]
Fault
Cause
Removal
System does not start.
Plug power supply is missing or
incorrectly inserted.
Plug connector check power
supply / plug in correctly.
No power at outlet.
Check the mains, remove error if
possible.
Suction power too low
(smoke hardly
extracted).
Filter element is saturated.
Replace the filter package,
dispose of old filter properly!
Filter elements are saturated because
no compressed air is connected.
Connect compressed air.
Damage at the extraction elements.
Replace the extraction elements.
Suction line contracted.
Check and fix.
Exhaust line contracted.
Check and fix.
Maybe throttle valves are used in the
suction line.
Adjust throttle valves.
10. List of spare parts
Filter element
Article no.
Filter cartridge, Type “PTFE”, 1,2m² (Ø218 x 305 mm)
9870003
Other parts
Article no.
Carbon brushes for AC turbine (2 pieces)
9870004
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11. Technical data
Supply voltage
V
230
Frequency
Hz
50
Type of current
Ph
1
Engine power
kW
2x 0,8
Air flow volume max.
m³/h
340
Negative pressure max.
Pa
20.000
Protection class
IP54
ISO class
F
Extraction performance
%
> 99
Width
Depth
Height
mm
mm
mm
300
300
810
Weight
kg
25
Sound pressure level
dB(A)
74
Allowed ambient temperature
°C
+5 to +35 (during operations)
-10 to +40 (during transport and storage)
Max. temperature of polluted air
at the capture point
°C
+50
Allowed max. humidity
%
70
Compressed air supply
dry / oil-free
Necessary external pressure
bar
see chapter “Connecting the compressed air supply”
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12. EC declaration of conformity
according to the Machinery Directive 2006/42/EG, Annex II, 1 A
TEKA Absaug- und Entsorgungstechnologie GmbH
Millenkamp 9, D-48653 Coesfeld
Tel.:[phone] E-Mail: [email protected] Internet: www.teka.eu
Designation of the device: DusToo
We hereby declare under our sole responsibility that the product mentioned above, from the serial
number A16000010011001 resp. the production number P33000010011001 on, conforms to the
following directives:
Machinery Directive: 2006/42/EG
Electromagnetic Compatibility: 2014/30/EC
Pressure equipment directive: 2014/68/EU
This declaration will become void if the device is exposed to modifications that are not approved by the
manufacturer in written form.
Authorized representative for the technical documentation:
TEKA Absaug- und Entsorgungstechnologie GmbH, Millenkamp 9, D-48653 Coesfeld
(Jürgen Kemper, managing director)
Coesfeld, 3rd january 2018
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