Teka FilterCube 4-IFA User manual

Operating instructions
(Translation of the original operating instructions)
FilterCube 4 - 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 5
3.1. Definition of the hazard symbols 5
3.2. General safety instructions 6
4. Storage, transport and installation of the device 7
5. Commissioning 8
5.1. Connecting the suction line and exhaust air line 9
5.2. Electrical connection 10
5.3. Precoating of the filter cartridges 11
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 12
6.1. Explanation of the operating elements 12
7. Maintenance 13
7.1 Reset to maintenance state 14
7.2. Cleaning the filter cartridges 15
7.3. Replacing the filter cartridges 16
7.4. Emptying the dust collecting tank 22
7.5. Draining the condensate 23
7.6. Precoating of new filter cartridges 24
7.6.1. Feeding the precoat via a FVS (TEKA spark pre-separator) 25
7.7. Cleaning/replacing the particle sensor 26
7.8. Replacing the filter mats at the control cabinet 27
8. Dismantling / Disposal 28
9. Diagnostics and troubleshooting 28
10. List of spare parts 30
11. Technical data 31
12. EC declaration of conformity 32
13. Training protocol 33
14. Maintenance intervals 34
14.1. Usage-related maintenance 34
14.2. General maintenance 35
14.2.1. Visual inspection of the device 35
14.2.2. Visual inspection of the pipelines for dust deposits 36
14.2.3. Visual inspection of the pneumatic pipes 36
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14.2.4. Functional test of the device 36
14.2.5. Electrical test of the electrical lines and earthing connections 37
14.2.6. Test of fixing of the mounted unit elements 37
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. 21382701
Pos.1
Pos.2
Pos.3
Pos.4
Dust collecting housing
Filter housing
Cleaning housing
Fan
Pos.5
Pos.6
Pos.7
Pos.8
Pos.9
Suction nozzle
Exhaust air nozzle
Connection for compressed air
Drain valve for compressed air
Silencer
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.
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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.
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.
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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.
Dangers arising from titling or functional impairments at its destination.
The unit may only be set up on a suitable surface. 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. The unit must be secured on the surface, for example using
lag bolts or stud bolts.
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.
● First the filter unit as delivered must be transported to its destination. There the filter unit must
be moved to an upright position. Therefore, lift the filter unit with lifting tools:
Unit type 1 (with sound insulation housing): Use the 4 lifting rings (A).
Unit type 2 (without sound insulation housing): Use the 4 lifting rings (B) at the fan housing.
Unit type 3 (with fan attached alongside): Use the lifting rings (C) for the filter unit. You can
move the fan by lifting it with fork lift forks underneath the bottom (D) of the fan.
Use appropriate lifting tools (forklift truck, transport crane,...) with a
minimum load-carrying capacity of 1000 kg. The filter unit must be secured against tilting
and slipping when it is moved, lifted or put down. No one is allowed to stand under or
beside the load. Use only appropriate ladder tools.
● For setting up the filter unit at its precise designated position, you can use the methods
mentioned for each unit type. When the mentioned method is used, it may only be transported a
short distance. The filter unit must be set up and fixed on a suitable surface.
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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.
If the air shall be directly sucked off by an upstream machine, the suction line must be connected to the
capture opening of the upstream machine.
The exhaust air pipe must be attached to the exhaust nozzle (see chapter 2.1).
In the case of an optional fan housing standing alongside, the filter unit and the fan must be connected
by means of a connecting pipe.
WARNING
Danger to life when reaching the fan impeller.
The exhaust air pipe must be attached before the commissioning.
If no exhaust air pipe is attached, the protective grille of the silencer must be installed.
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5.2. Electrical connection
WARNING
Risk of electric shock.
Electrical plants and equipment may only be built, modified and maintained by a qualified
electrician or under the direction and supervision of a qualified electrician. Do not work on
live electrical components and elements if you are not sure that these are indeed
disconnected. If necessary, disconnect the device from the mains. The operator is
responsible for a potential-free balance of the equipment.
If the unit is equipped with a frequency converter, then it may only be operated on networks
with an AC/DC sensitive RCCB. For frequency converter operation, the cross section of the
protective conductor
● must be at least 10mm²,
● and must be at least equal to the size of the operator side outer conductor
cross-section.
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.
● Mount the housing of the external control (if it is not mounted on the device itself) close to the
device on the wall or at any other appropriate mounting point. Or mount the control together
with a cabinet console on a suitable surface, for example using lag bolts or heavy-duty anchors.
The housing is not suited for outdoor installation.
● Connect all visible cables and hoses are according to their functions. When delivered they are
labelled according to their functions. When connecting to the control, please observe the
specifications on the circuit diagram which is attached to the control.
● Connect the unit to the power supply.
● Check if the direction of fan rotation is correct (This is not necessary in the case of units with a
frequency converter). A wrong rotation direction can be identified thanks to the sticker sticked to
the fan scroll which is showing the direction. Compare the rotation direction on the sticker to the
rotation direction of the motor cooling fan when the motor is running down after being switched
off. If the motor rotates in the wrong direction, disconnect the device from the power supply and
exchange two phases at the supply line to the control.
When the fan rotates in the wrong direction, the extraction capacity is
reduced.
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