Teka Handycart DC User manual

Operating instructions
(Translation of the original operating instructions)
Handycart DC
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. System extensions / distinctions between versions 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. Installing the automatic cleaning mechanism 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 11
6.1. Explanation of the operating elements 11
6.2. Switching on / off the Handycart 12
6.3. Setting the automatic filter cartridge cleaning 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. Replacing the filter mats for the air outlet grille 20
8. Dismantling / Disposal 20
9. Diagnostics and troubleshooting 21
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10. List of spare parts 22
11. Technical data 23
12. EC declaration of conformity 24
13. Training protocol 25
14. Maintenance intervals 26
14.1. Usage-related maintenance 26
14.2. General maintenance 27
14.2.1. Visual inspection of the device 27
14.2.2. Functional test of the device 28
14.2.3. Electrical test of the electrical lines and earthing connections 28
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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. 11195705
Pos.1
Pos.2
Pos.3
Pos.4
Pos.5
Pos.6
Operating panel of the control
Dust collecting housing
Filter housing
Turbine housing
Suction nozzle
Exhaust grille
Pos.7
Pos.8
Pos.9
Pos.10
Pos.11
Connection for mains cable
Connection for external control unit
Swivel castor
Toggle lever
Connection for measuring hose (2x)
The system can be optionally equipped with an automatic cleaning mechanism:
Pos.12
Pos.13
Cleaning housing
Clock generator
Pos.14
Pos.15
Connection for compressed air
Connection for control cable (2x)
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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.
2.4. System extensions / distinctions between versions
In the standard version, the filter cartridge is cleaned manually.
The system can be optionally equipped with an automatic cleaning mechanism which automatically
cleans the filter cartridge. See section 2.1 to determine the equipment version of your system. These
Operating Instructions indicate the differences between the versions wherever necessary.
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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.
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
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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 only 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.
(This note is only relevant if the system is equipped with the optional automatic cleaning
mechanism.)
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. Installing the automatic cleaning mechanism
This section is only relevant if the system is equipped with the optional automatic cleaning
mechanism.
● Release the toggle levers (see section 2.1) and remove the turbine housing.
● Place the cleaning mechanism housing on the filter housing (see section 2.1). When you do
this, the outlet hole (A) must face downwards.
● Place the turbine housing on the cleaning mechanism housing.
● Fix the housing in place using the toggle levers. When you do this, you should also use the long
locking hooks supplied (B) in order to compensate for any height differences.
● Connect the supplied control cable to the clock generator (C) and the interface (D).
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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
This section is only relevant if the system is equipped with the optional automatic cleaning
mechanism.
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 1,5 bars and
maximum of 2,0 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).
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.
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6.2. Switching on / off the Handycart
The Handycart can be switched on/off via an external control.
Handycart switched off.
The Handycart is switched on via
the external control.
The Handycart is switched off via
the external control.
The Handycart can also be switched off/on via its own membrane switch panel. (To this end it is
necessary to separately switch on the external control.)
Handycart in operating condition.
The Handycart is switched off via
the membrane switch panel.
The Handycart is switched on via
the membrane switch panel.
IMPORTANT: The Handycart is switched on via the external control - but the Handycart is
not starting the extraction. What is going wrong?
Handycart switched off.
The Handycart is switched on via
the external control, but the
Handycart is not reacting.
Solution: In this case, the separate
on/off switch at the membrane
switch panel must be separately
activated in addition.
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6.3. Setting the automatic filter cartridge cleaning
This section is only relevant if the system is equipped with the optional automatic cleaning
mechanism.
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
Handycart without automatic cleaning mechanism:
● 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.
Handycart with automatic cleaning mechanism:
● 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.
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7.2. Cleaning the filter cartridges
Handycart without automatic cleaning mechanism:
The filter cartridges are reusable filters and can be cleaned. The cleaning of the filter cartridges is
carried out manually.
The degree of pollution of the filter cartridges is electronically monitored. When the maximal admissible
differential pressure value is reached, the device triggers “filter alarm” (see chapter “description of the
control elements”). Now a cleaning is necessary. If despite of the cleaning of the filter cartridge the
alarm value is not undercut anymore, the filter cartridge must be replaced. (see chapter: “Replacing the
filter cartridges”).
● Close all front service doors in case they are open.
In case the service doors are open, dust can escape during the cleaning.
● Open the toggle levers and remove the turbine housing.
● Use a compressed air pistol for the cleaning. These must be connected to the external
compressed air supply of the operator.
The compressed air must be dry and oil-free. The operating pressure must be
between 1,5 and 2,0 bars.
● Hold the compressed air pistol into the interior of the filter cartridge. Blow steadily with the
compressed air pistol into the crinkles of the filter cartridge. Clean it for at least 5 minutes.
● Put the turbine housing back on the filter housing. Close the toggle levers.
Handycart with automatic cleaning mechanism:
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
Handycart without automatic cleaning mechanism:
Whirling up dust is possible due to the polluted filter cartridges.
The filter cartridges must be cleaned before being replaced. Proceed as described in chapter
“cleaning of the filter cartridges”. After cleaning the filter cartridges wait about 5 minutes
before opening the service door of the filter housing.
Handycart with automatic cleaning mechanism:
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 maintenance door of the filter cartridges.
● Resolve the clamping screw (pos. A) of the cartridge holder (pos. B).
● Hook off the cartridge holder from the cartridge guiding (pos. E) and take it out of the device
together with the filter cartridge (C).
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● Push the new filter cartridge into the cartridge holder.
Only use TEKA spare filters. Otherwise the proper functioning of the unit is
not guaranteed.
● Fasten the clamping screw of the cartridge holder.
● Close the service door.
After the filter cartridge has been replaced, it is necessary to enter the supplied filter code at the control
unit:
● Bring the system into the "ready to operate" condition and then switch it on.
● Select the menu item “Filter code” with the help of Enter and the button +/-.
● Enter the filter code enclosed in the filter via the button +/- and confirm via Enter.
● The message “Filter OK” appears in the display.
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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
Handycart without automatic cleaning mechanism:
Whirling up dust is possible due to the polluted filter cartridges!
The filter cartridges must be cleaned before emptying the dust collecting tank. The
proceeding of the cleaning is described in the chapter “Cleaning of filter cartridges”. After
cleaning the filter cartridges wait about 5 minutes before opening the service door.
Handycart with automatic cleaning mechanism:
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 service door of the filter housing (see chapter 2.1).
● Carefully pull the dust collecting tank (A) 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 filter housing.
● Close the service door.
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7.5. Replacing the filter mats for the air outlet grille
The filter mat is located in the ventilation grille of the control cabinet. The filter mat must be checked
regularly and changed if necessary. This check depends on the degree of contamination. We
recommend to stock with filter mats early on (see spare parts list).
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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