Teka LMD 501 User manual

Operating instructions
(Translation of the original operating instructions)
TEKA - LMD 501
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 8
5.1. Connecting an extraction element 8
5.2. Electrical connection 8
6. Operating the system 9
6.1. Explanation of the operating elements 9
6.2. Connection of an external control 9
7. Maintenance 10
7.1. Reset to maintenance state 10
7.2. Replacing the prefilter mat 11
7.3. Replacing the particle filter 12
7.4. Replacing the activated carbon / the activated carbon cassette 12
7.4.1. Replacing the activated carbon 13
7.4.2. Replacing the activated carbon cassette 15
8. Dismantling / Disposal 15
9. Diagnostics and troubleshooting 16
10. List of spare parts 17
11. Technical data 17
12. EC declaration of conformity 18
13. Training protocol 19
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14. Maintenance intervals 20
14.1. Usage-related maintenance 20
14.2. General maintenance 20
14.2.1. Visual inspection of the device 21
14.2.2. Functional test of the device 21
14.2.3. Electrical test of the electrical lines and earthing connections 22
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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. 13153701
Pos.1
Pos.2
Pos.3
Pos.4
Pos.5
Pos.6
Pos.7
Operating panel of the control
Particle filter housing
Activated carbon housing
Turbine housing
Silencing housing
Particle filter
Prefilter mat (inserted into particle filter)
Pos.8
Pos.9
Pos.10
Pos.11
Pos.12
Pos.13
Activated carbon cassette
Suction nozzle
Exhaust grille
Mains cable with plug
Connection for external control unit
Swivel castor
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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). First of all, the
coarse particles are separated at the prefilter mat in the filter section of the unit. The subsequent particle
filter cleans even fine smokes and dusts. The activated carbon filter absorbs gases and unpleasant
odours. 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.
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 intended for extraction and filtration of fumes that result from lasers or soldering jobs.
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.
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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
necessary, disconnect the device from the electric power supply and secure it against
unauthorized restarting.
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4. Storage, transport and installation of the device
WARNING
Risk of injury from tilting or unmounted components when stored or transported.
The device must be secured against tilting and slipping when it is stored or transported. Do
not stand under or next to the floating load. Lift trucks, forklift trucks and transport cranes
must have a sufficient minimum load bearing capacity. 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.
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)
5.2. Electrical connection
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.
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● Reconnect the mains cable (see chapter 2.1) to the power supply.
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.
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:
“Sub-D9”
Number of pins:
9
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
“Operation”
Pin serves for the evaluation of the operational control.
(NO: normaly open)
5, 6
External message
“Fault”
Pin serves for the evaluation of an fault indication.
(NO: normaly open)
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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 due to contact with
contaminated filter elements.
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.
7.1. Reset to maintenance state
● 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.
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7.2. Replacing the prefilter mat
The prefilter mat is installed upstream to the particle filter and separates the coarse particles. This
extends the service life of the particle filter.
The prefilter mat must be changed after a certain number of operating hours. The time depends on the
amount of accumulated dust, and therefore cannot be determined beforehand. At the latest, the prefilter
mat must be changed when changing the particle filter.
CAUTION
Whirling up dust is possible.
The prefilter mat is a disposable filter element. Do not try to clean the filter element.
● Open the service door of the particle filter housing (see chapter 2.1).
● Lower the lifting device (A) by turning the clamping screw (B). Therefore, use the hexagon key
that is located on the right of the clamping screw.
● Carefully pull the particle filter (see chapter 2.1) out of the housing.
● Remove the prefilter mat from the particle filter and dispose of or store it according to the
regulations.
● Put a new prefilter mat into the particle filter.
Only use TEKA spare filters. Otherwise the proper functioning of the unit is
not guaranteed.
● Push the particle filter back into the particle filter housing.
● Elevate the lifting device by turning the clamping screw so that the particle filter is pressed
tightly against the above housing.
● Close the service door.
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7.3. 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.
When replacing the particle filter, the prefilter mat must be replaced as well.
● Open the service door of the particle filter housing (see chapter 2.1).
● Lower the lifting device (A) by turning the clamping screw (B). Therefore, use the hexagon key
that is located on the right of the clamping screw.
● Carefully pull the particle filter (see chapter 2.1) out of the housing.
● Push the new particle filter back into the particle filter housing.
Only use TEKA spare filters. Otherwise the proper functioning of the unit is
not guaranteed.
● Elevate the lifting device by turning the clamping screw so that the particle filter is pressed
tightly against the above housing.
● Close the service door.
7.4. 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.
However, at the latest when the main filter of the device is replaced, the activated carbon should be
replaced as well. For it is also the pollution of the activated carbon which lowers the (entire) extraction
capacity of the filter unit.
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.
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7.4.1. 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).
Therefore, use the hexagon key
that is located on the right of the
clamping screw.
● Carefully pull the entire filter pack,
incl. the activated carbon cassette
(see chapter 2.1), out of the
housing.
● 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.
● Remove the bottom filter fleece
mat.
● Insert the new filter fleece mat
here. This must completely cover
the holes in the grille at the base.
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● The new activated carbon must be
carefully filled into the activated
carbon cassette. Gradually fill with
a number of smaller quantities of
activated carbon, spreading it out
evenly and gently pressing down
on it as you do so.
Only use TEKA spare
filters. Otherwise the proper
functioning of the unit is not
guaranteed.
● The cassette must be filled with
activated carbon up to the height
of the support surface (A) and
levelled off.
● Place the new top filter fleece mat
over the activated carbon. It may
be necessary to cut the filter fleece
mat to the right size. The size
must correspond to the
dimensions of the cover.
● Screw the cover back on again.
When you do this, the cover must
press the top filter fleece mat
against the support surface of the
activated carbon cassette all the
way round.
● Push the filter pack back into the
filter housing. Make sure that the
filter elements are inserted in the
correct order.
● Elevate the lifting device by turning
the clamping screw so that the
entire filter pack is pressed tightly
against the above housing.
● Close the service door.
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7.4.2. Replacing the activated carbon cassette
● Open the service door of the activated carbon housing (see chapter 2.1).
● Lower the lifting device (A) by turning the clamping screw (B). Therefore, use the hexagon key
that is located on the right of the clamping screw.
● Carefully pull the entire filter pack, incl. the activated carbon cassette (see chapter 2.1), out of
the housing. (If a spacer frame is mounted in addition, it must be carefully removed as well.)
● Replace the activated carbon cassette.
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.
● Elevate the lifting device by turning the clamping screw so that the entire filter pack is pressed
tightly against the above housing.
● Close the service door.
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.
Error messages of the control unit are described in the enclosed operating manual of the control
unit.
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!
Damage at the extraction elements.
Replace the extraction elements.
Suction line contracted.
Check and fix.
Exhaust line contracted.
Check and fix.
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10. List of spare parts
Filter element
Article no.
Prefilter mat “M5” (10 pieces / 572 x 268 x 20 mm)
10056
Particle filter “H13” (610 x 305 x 150)
10035
Activated carbon cassette, 7 kg activated carbon (610 x 305 x 100)
or:
7 kg activated carbon, including filter fleece mats
97052
100197501
11. Technical data
Supply voltage
V
230
Frequency
Hz
50
Type of current
Ph
1.
engine power
kW
2,4
Air flow volume max.
m³/h
640
Negative pressure max.
Pa
15000
Protection class
IP54
ISO class
F
Extraction performance
%
>99
Width
Depth
Height
mm
mm
mm
365
768
801
Weight
kg
70
Sound pressure level
dB(A)
70
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
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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: TEKA-LMD 501
We hereby declare under our sole responsibility that the product mentioned above, from the serial
number A14500010011001 resp. the production number P28000010011001 on, conforms to the
following directives:
Machinery Directive: 2006/42/EG
Electromagnetic Compatibility: 2014/30/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 2017
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13. Training protocol
Designation of the device: TEKA-LMD 501
(This form can be used by the operator to document the training of the employees. Training should be performed by
authorized personnel only. Refer to the instructions in Chapter "Safety Instructions")
By his signature, the employee confirms that he has been instructed regarding the following items:
Instruction
completed
Description of the device
Operation and application of the device
Explanation of the safety instructions
Behavior in case of fire
Explanation of the operation elements
Change and dedusting of the filter elements
Appropriate disposal
Maintenance works / Maintenance intervals
Name of the employee (legible)
Signature
Introduction through (legible):
Signature:
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14. Maintenance intervals
14.1. Usage-related maintenance
The described maintenances become necessary through the demands of the system operations. The
maintenance intervals are recommendations. Depending on the application (multi-shift operation, dust
generation, ...) it may make sense for the operator to change the intervals of maintenance, replacing
and cleaning.
Maintenance work must always be documented by means of a protocol.
The approach of the maintenance measures is described in chapter "Maintenance".
Maintenance work
Chapter
Maintenance interval
recommended by TEKA
determined by the operator
Replacing the particle filter
7.3
The saturation of the particle filter is automatically monitored by
the filter unit and thus is not subject to a maintenance interval.
The filter unit triggers an alarm when a replacement of the
particle filter is necessary.
Replacing the activated carbon / the
activated carbon cassette (or check
the degree of pollution)
7.4
when odours occur /
when replacing the main filter
Replacing the prefilter mat
(or check the degree of pollution)
7.2
monthly
14.2. General maintenance
The described maintenances are independent from the demands of the system operations.
The operator is obliged to carry out repeated inspections and functional tests according to national
regulations. If not otherwise covered by national regulations, the described maintenance intervals must
be respected.
Maintenance work must always be documented by means of a protocol.
Maintenance work
Chapter
Maintenance interval
Visual inspection of the device
14.2.1
weekly
Functional test of the device
14.2.2
monthly
Electrical test of the electrical lines and earthing connections
14.2.3
annually
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