Teka StrongMaster 1-IFA User manual

Operating instructions
(Translation of the original operating instructions)
StrongMaster 1 - IFA
StrongMaster 2 - IFA
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 3
2 Description of the system elements 4
2.1 Illustration of the system elements 4
2.2 Functionality of the system 4
2.3 Intended use 5
2.4. Residual risk 5
3 Safety instructions 6
3.1 Definition of the hazard symbols 6
3.2 General safety instructions 6
4 Storage, transport and installation of the device 7
5 Commissioning 8
5.1 Connecting an extraction element 8
5.2 Electrical connection 9
5.3 Precoating of the filter cartridges 9
6 Operating the system 10
6.1 Explanation of the operating elements 10
7 Maintenance 11
7.1 Reset to maintenance state 12
7.2 Cleaning the filter cartridges 12
7.3 Replacing the filter cartridges 13
7.4 Emptying the dust collecting tank 17
7.5 Precoating of new filter cartridges 18
8 Dismantling / Disposal 19
9 Diagnostics and troubleshooting 19
10 List of spare parts 20
11 Technical data 21
12 EC declaration of conformity 22
13 Training protocol 23
14 Maintenance intervals 24
14.1 Usage-related maintenance 24
14.2 General maintenance 24
14.2.1 Visual inspection of the device 25
14.2.2 Functional test of the device 25
14.2.3 Electrical test of the electrical lines and earthing connections 26
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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. 13464702
Pos.1
Pos.2
Pos.3
Pos.4
Pos.5
Pos.6
Operating elements
Dust collecting housing
Filter housing
Fan housing
Silencing housing
Service door for cleaning the filter
cartridges
Pos.7
Pos.8
Pos.9
Pos.10
Pos.11
Suction nozzle (StrongMaster 1: 1x,
StrongMaster 2: 2x)
Exhaust grille
Mains cable with plug
Swivel castor
Signal horn
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.
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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 dusts and fumes that result from thermal joining
and cutting of metals. The filter unit is amongst others suitable for separating welding smokes of
unalloyed and alloyed steels as well as of high-alloy chromium-nickel steels and therefore meets the
highest welding fume separation category “W3” according to DIN EN ISO 21904-1 / -2.
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. Residual risk
CAUTION
Danger due to possible hazardous materials in the exhaust air flow.
Because the unit does not monitor the quality of the air in the exhaust air flow, we
recommend that you always guide the exhaust air flow exiting our unit to areas (e.g. to the
outside into the open air) in which there is no danger to any living being. To do this, it is
necessary to fit a suitable exhaust air line at the filter unit.
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3 Safety instructions
3.1 Definition of the hazard symbols
The device is constructed according to the state of the art and the recognised safety regulations.
Nevertheless, during use threats to life and limb of the user or other persons may arise. The impairment
of the machine or other property are also possible. In these instructions we warn by using corresponding
indications.
WARNING
WARNING
These instructions are made in case of risks that can lead to injury or death.
CAUTION
CAUTION
These instructions are made in case of risks that can lead to injury.
NOTICE
NOTICE
These instructions are made in case of risks that can lead to material damages.
Information notes are no hazard warnings; they call attention to useful information.
3.2 General safety instructions
WARNING
Dangers arising from improper use / unauthorised operations.
The operator must ensure that their authorised personnel are familiar with all the safety
indications in this manual in advance. The operator is responsible for ensuring that all work
is carried out by authorised and qualified personnel. We therefore recommend using the
training protocol on the last page for that purpose (see chapter “Training protocol”).
Laymen are allowed to operate the device after having received the necessary instructions.
But they are not allowed to carry out any installation, repair or maintenance work.
Dangers arising from fire.
In case of fire, if possible, switch the unit immediately off or disconnect it from the power
supply. Fire extinguishing measures which the operator is obliged to determine beforehand
must be initiated immediately.
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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).
The assembly of a suction arm is described in the separate operating manual.
When using a detection element with extraction hood, the extraction hood must track the welding seam,
possibly taking advantage of the thermally induced welding fume movements.
However, it is important to ensure that connections between the workpiece and the
extractor hood (and generally between the workpiece and filter device) are avoided, so that, if
necessary, the welding current cannot flow back through the protective conductor of the filter
device to the welding machine.
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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.
● Reconnect the mains cable (see chapter 2.1) to the power supply.
● Make sure that the fan impeller rotates in the required direction when switching it on for the first
time. If not, it results in a low extraction capacity. For visual inspection, there is a sticker
attached to the bottom of the dust collecting housing (see chapter 2.1). For the connection
points of 400V and 500V the rotating field might be incorrectly set and must be changed, if
necessary. Briefly switch the device on and off. The fan slowly starts running and the rotation
direction can be compared to the sticker.
When the fan rotates in the wrong direction, the extraction capacity is
reduced.
5.3 Precoating of the filter cartridges
For a longer service life of the filter cartridges we recommend to pretreat them with a filter aid. The
precoating can only be carried out during the commissioning at the operation site. When the operator
orders and installs new filter cartridges, we recommend to also precoat them before the commissioning.
Please read and refer to "Precoating new filter cartridges" in the chapter "Maintenance". There
you can also find a description of the operating method of the precoat.
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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.
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.
Signal horn
Honking signals 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.
Operating hour counter
The number of operation hours during which the device was in
operation is shown.
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