Teka CartMaster wall 1-IFA User manual

Operating instructions
(Translation of the original operating instructions)
CartMaster wall 1 - IFA
CartMaster wall 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 5
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
4.1. Mounting of the unit to the wall 7
5. Commissioning 9
5.1. Connecting the suction line and exhaust air line 10
5.2. Electrical connection 11
5.3. Precoating of the filter cartridges 12
5.4. Connecting the compressed air supply 12
5.4.1. Compressed air supply for the cleaning of the filter cartridges 12
6. Operating the system 13
6.1. Explanation of the operating elements 13
7. Maintenance 14
7.1. Reset to maintenance state 15
7.2. Cleaning the filter cartridges 15
7.3. Replacing the filter cartridges 16
7.4. Emptying the dust collecting tank 21
7.5. Draining the condensate 22
7.6. Precoating of new filter cartridges 23
7.7. Cleaning the copper baffle plate 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 31
14.2.1. Visual inspection of the device 32
14.2.2. Visual inspection of the pipelines for dust deposits 32
14.2.3. Visual inspection of the pneumatic pipes 32
14.2.4. Functional test of the device 33
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14.2.5. Electrical test of the electrical lines and earthing connections 33
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. 12471707
Pos.1
Pos.2
Pos.3
Pos.4
Pos.5
Filter housing
Cleaning housing
Fan
Suction nozzle
Exhaust air nozzle
Pos.6
Pos.7
Pos.8
Pos.9
Pos.10
Connection for compressed air
Drain valve for compressed air
Dust collecting tank
Toggle lever
Wall console
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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 outside via the exhaust air pipe or 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 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.
Risk of injury arising from the falling unit at its destination.
The unit must be firmly mounted to the destined wall. The wall must be vibration-free and
vertical. The operator must check if the wall provides a sufficient bearing capacity.
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 outdoors. In this case contact
the manufacturer in order to find out if a caping or a trace heating system are necessary.
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4.1. Mounting of the unit to the wall
Wall brackets are already attached to the filter unit upon delivery.
● The two other wall brackets must be screwed to the wall. Pay attention to an identical distance
"X".
● Put the filter unit with its wall brackets on the wall brackets attached to the wall and screw them
by means of the delivered screws.
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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.
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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).
CAUTION
Danger for the respiratory tract arising from polluted ambient air. Dust deposits in the
suction pipe are possible.
Only operate the system if the necessary suction line is fitted. The suction line must be
dimensioned according to the application in such a way that, if possible, no dust deposits
occur in the suction line. If this has not already been carried out by TEKA, a suitably qualified
employee must be consulted. If the suction line includes extraction elements (e.g. suction
arms, pipe grills, etc.), these must also be included in the layout. If this is the case then users
must be informed of whether extraction elements can be used simultaneously and, if this is
possible, then which. The regulating devices (e.g. throttle valves) of each single extraction
element must also be set appropriately during the final commissioning.
Depending on the application, the suction pipe must be equipped with extraction elements (suction arm,
extraction hose, round duct grille, etc.). When using a capture element with an extractor cowl, the
extractor cowl must follow the weld seam, if possible by using the movement of the welding fume
caused be thermal influences.
: You have to make sure that connections between the workpiece and the suction
hood (and in general between the workpiece and the filter unit) are avoided in order to prevent
the welding current from flowing back to the welding machine via the protective conductor of the
filter unit.
The exhaust air pipe must be attached to the exhaust nozzle (see chapter 2.1).
WARNING
Danger to life when reaching the fan impeller.
The required exhaust air pipe must be attached before the commissioning.
The assembly of a suction arm is described in the separate operating manual.
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