Teka Spark User manual

Operating instructions
(Translation of the original operating instructions)
Spark separator
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 Intended use 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 the suction line and exhaust air line 8
5.1.1 Positioning the perforated sheet 9
5.2 Electrical connection 9
5.3 Water supply / water quality 10
6 Operating the system 11
6.1 Explanation of the operating elements 11
6.2 Functioning of the control system 11
6.3 Error reporting of the control system 12
6.4 Set the sensitivity of the level monitoring relay 12
7 Maintenance 13
7.1 Reset to maintenance state 13
7.2 Cleaning the dust collecting tank 14
7.3 Cleaning of the spark separator 14
7.4 Maintenance of the filling level sensors 14
8 Dismantling / Disposal 15
9 List of spare parts 15
10 Technical data 15
11 EC declaration of conformity (according to 2001/95/EC) 16
12 Maintenance intervals 17
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12.1 Usage-related maintenance 17
12.2 General maintenance 17
12.2.1 Visual inspection of the device 18
12.2.2 Visual inspection of the pipelines for dust deposits 18
12.2.3 Electrical test of the electrical lines and earthing connections 18
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. 11283702
Pos.1
Pos.2
Pos.3
Pos.4
Pos.5
Pos.6
Pos.7
Pos.8
Operating panel of the control
Connection for mains cable
Exhaust air nozzle*
Suction nozzle* (air inlet side)
Dust collecting tank (filled with water)
Toggle lever
Ball valve ¾“ for water connection
Wastewater connection ¾”
Pos.9
Pos.10
Pos.11
Pos.12
Pos.13
Pos.14
Pos.15
Pos.16
Magnet valve
Service door
Filling level sensor 3-pin
Filling level sensor 1-pin
Housing for filling level sensor
Optical filling level indicator
Perforated sheet (exhaust air side)
Bar heater (option)
* = which is the suction nozzle and which the exhaust air nozzle is defined at the time of assembly (see
section “Connecting the suction line and exhaust air line”).
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2.2 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 TEKA spark separator is a safety device to protect the filtering unit from sparks and glowing
particles, especially during welding. The sparks are extinguished when the air flow strikes the surface of
the water. Light particles are also moistened with water through the simultaneous air deflection within
the housing.
WARNING
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.
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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.
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 heavy-duty anchors.
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.
If the unit still be placed in the outdoor area, the dust collecting tank be equipped with a
heating element (bar heater, see chapter 2.1). In case of outdoor installation the magnet
valve (see chapter 2.1) must also be installed inside the building. The operator has to ensure
that the water supply of magnet valve for spark separator remains frost-free.
If the unit is placed in the outdoor area, the filter level control must be dismantled and placed
indoors. The control and measurement cables to the spark separator are embarrassed to
meet new or renew.
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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.
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 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.
The exhaust air pipe must be attached to the exhaust nozzle (see chapter 2.1). (The exhaust air line
connects the spark separator to the filter unit.)
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5.1.1 Positioning the perforated sheet
If the perforated sheet (see chapter 2.1) is to fulfil its function it must be mounted on the exhaust air
side, i.e. on the side on which the exhaust air nozzle is located (see section 2.1). Before taking the
equipment into service, it is therefore necessary to check that the perforated sheet is mounted on the
correct side.
● Open the service door (see chapter 2.1).
● If this has not already been done, position the perforated sheet on the exhaust air side. Push
the perforated sheet fully into the guide.
Make sure that the handle is at the front.
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.
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.
● Connect the mains cable (see chapter 2.1) to the power supply.
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5.3 Water supply / water quality
Due to the moistening of the outlet air, the water is little by little extracted from the filter unit. That is why
water must be regularly be refilled. It is ensured by the automatic monitoring of the water level and the
automatic refilling through the electrovalve.
WARNING
Danger due to unhealthy exhaust air released by contaminated water.
Make sure that the supplied water is of irreproachable hygienic and microbiological quality.
The supplied water must be clear, colourless and odourless. The water must also be
“non-putrefactive in 5 days”.
Equally, in the event of a system stoppage lasting 5 or more days, the operator must check
whether the water still meets the quality requirements or whether it needs to be changed. As
soon as an extended stoppage of the system is envisaged, it is urgently recommended to
drain off the water for this period.
The operator must also make sure that the admixture of the water with the extracted
dusts/fumes does not result in any interactions that jeopardize fulfilment of the above quality
requirements.
NOTICE
Possible damage to equipment (valves, supply line, etc.) due to contaminated water.
Make sure that the supplied water is free from suspended matter and other contaminants.
● During operation, the ball valve (see chapter 2.1) has to be equipped with an open water supply
of ¾“.
● When carrying out cleaning operations, you have to pay attention that no polluted water enters
the canalisation.
● Before switching on the unit for the first time, it is advisable to let in water manually until the
water level reaches the middle of the water level indicator.
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