Teka WNA-AL User manual

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 5
2.3. Intended use 6
3. Safety instructions 6
3.1. Definition of the hazard symbols 6
3.2. General safety instructions 7
4. Storage, transport and installation of the device 7
5. Commissioning 9
5.1. Connecting the suction line and exhaust air line 10
5.2. Electrical connection 11
5.3. Water supply / water quality 12
5.3.1. Additive: corrosion protection "hebro®protect 95-103" (optional) 13
5.3.2. Additive: Defoamer (optional) 13
5.4. Installing a water discharge as an overfill protection 13
6. Operating the system 14
6.1. Explanation of the operating elements 14
7. Maintenance 15
7.1. Reset to maintenance state 15
7.2. Cleaning/replacing: aluminium mesh filter and droplet separator 16
7.3. Cleaning the mud container 16
7.4. Maintenance of the magnet valves 17
8. ATEX operation 18
8.1. ATEX zoning for WNA-AL 18
8.2. Sources of ignition 19
8.2.1. Evaluating the risk of ignition in accordance with DIN EN 80079-36 19
9. Dismantling / Disposal 20
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10. Diagnostics and troubleshooting 20
11. List of spare parts 22
12. Technical data 23
13. EC declaration of conformity 24
14. ATEX Annex to the EG Declaration of Conformity 25
15. Training protocol 26
16. Maintenance intervals 27
16.1. Usage-related maintenance 27
16.2. General maintenance 27
16.2.1. Visual inspection of the device 28
16.2.2. Visual inspection of the pipelines for dust deposits 28
16.2.3. Functional test of the device 29
16.2.4. Electrical test of the electrical lines and earthing connections 29
16.2.5. Test of fixing of the mounted unit elements 29
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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: +49 2541-84841-0
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. 19072709
Pos.1
Pos.2
Pos.3
Pos.4
Pos.5
Pos.6
Fan
Suction nozzle
Exhaust air nozzle
Silencer
Ball valve ¾“ for water connection
Wastewater connection 2”
Pos.7
Pos.8
Pos.9
Pos.10
Pos.11
Pos.12
Cleaning flap
Magnet valve
Service door
Aluminium mesh filter
Droplet separator
Protective intervention grid
2.2. Functionality of the system
The filter unit serves to suck off and filter polluted air (according to the intended use). In the filter section
of the unit, the air is dragged through a water bath by means of baffle plates. The contact with water and
the strong turbulences ensure that a majority of the dusts are bound in the water. The separated dust
particles settle as sludge in the lower water tank. 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 filter unit is intended for the extraction and filtration of grinding dust. The filter unit is also suitable for
extracting aluminium and magnesium dusts. (Please also see the section on “ATEX operation”)
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 gases,
hybrid mixtures, etc. The device must not be operated in explosive zones.
Explosion hazard!
If aluminium and a spark producing material are processed alternately, the wet cyclone
separator and the ducting have to be cleaned from dry, adhering dust before the material is
changed.
As the accumulation of aluminium grinding dust produces a potential risk of explosion, the
interior of the WNA-AL protected against sparking due to the explosion-proof engine and the
grounded internal parts. The operator has to ensure that in the environment of the unit, such
accumulations are not produced, e.g. in ensuring a sufficient ventilation of the space.
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.
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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.
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.
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 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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● First the filter unit as delivered must be transported to its destination. Then lift the filter unit off
the pallet. Therefore use the lifting rings (B).
Use appropriate lifting tools (forklift truck, transport crane,...) with a
sufficient minimum load-carrying capacity. 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 the
load. Use only appropriate ladder tools.
● Optionally, the filter component (A) can be set on the supplied adjustable feet (C). This effects
the future working height of the filter unit. Therefore, lift up the filter component (A) with a lifting
tool for 0.5 meters.
● Mount the bow silencer (D) on the fan. Use the lilfting rings (E) to lift. In doing so, also adjust the
leveling feet (F) (only used for larger devices), so that the weight of the silencer is caught by the
lid.
● Screw the bow silencer (D) using the 2 screws (G). For this purpose, the 2 supplied contact
discs must be used.
● Then the filter unit must be set up on a suitable surface at its exact intended destination. Use
the lifting rings (B) to transport the filter unit there.
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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.
If the wet separator is equipped with a frequency converter, the setting of the correct volumetric
flow rate is part of the commissioning. It must be set in the control. Please refer to the instructions
in the separate operating manual of the control unit.
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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. 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.
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).
WARNING
Danger to life when reaching the fan impeller.
The required exhaust air pipe must be attached before the commissioning.
WARNING
Explosion hazard due to the formation of explosive deposits or explosive mixtures.
The suction ducting has to be dimensioned so that the air speed within the tube is at least
20m/s and that it is grounded against electrostatic charge. The lines must be kept as short as
possible and must be laid to the extraction point in a way that optimizes the flow in order to
prevent any deposits from forming in the lines. The lead of the exhaust air has to be
continually ascending to prevent the creation of explosive mixtures.
If the suction line is laid as a rising/falling structure in such a way that hydrogen might
accumulate there then the line must be equipped with a suitable vent hole prior to
commissioning. In this case, the hydrogen must be able to escape unobstructed. The vent
hole must not be covered or sealed. We recommend a hole of min. Ø5mm and this should be
identified using the enclosed labels:
If the clean air cannot be led outside, the operator must ensure, for example by providing
adequate technical/natural ventilation, that hydrogen is unable to accumulate in potentially
dangerous quantities inside the premises.
If the operator cannot exclude the possibility that effective sources of ignition may occur, then
the concentration of the dust arising at the extraction point within the line and the filter unit
must always be 50% by mass below the lower explosion limit (LEL).
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According to the temperature and the relative air humidity of the extracted air, the exhaust air can
also be moisture. In every case, the exhaust air has to be returned outside so that the work-ing
space is not too highly moisture which can lead to the formation of condensate.
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.
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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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.
The water quality has a major impact on the functionality of the unit. It cannot always be determined in
advance if an additive is necessary or not. Damages due to corrosion or improper use are therefore
excluded from warranty. A regular check of the water quality (salt/lime content, degree of pollution, pH
value) is essential. Please also note the information about the additives.
● During operation, the ball valve (see chapter 2.1) has to be equipped with an open water supply
of ¾“.
● The wastewater connection (see chapter 2.1) is equipped with a 2“ shut-off valve.
● When carrying out cleaning operations, you have to pay attention that no polluted water enters
the canalisation.
● The quality of the supplied water must not affect the condition of the unit. We recommend fresh
water with a pH-value of about 7.
● Before switching on the unit for the first time, it is advisable to let in water manually via the open
cleaning flap (see chapter 2.1) until the water level reaches the middle of the water level
indicator. The level indicator is located inside the filter housing, below the cleaning flap.
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5.3.1. Additive: corrosion protection "hebro®protect 95-103" (optional)
A corrosion-protective agent should be added to the water in order to prevent the formation of rust,
especially in case of separation of acidly reacting substances. This is primarily required when separating
metal dust and scale dust.
If you ordered a corrosion-protective agent when ordering the unit, add it to the water when
commissioning the unit.
As water is refilled from time to time, the corrosion-protective agent must be refilled in small doses as
well (in case you use a corrosion-protective agent). The water consumption (see chapter "Technical
data") depends on several service factors and must be observed or determined individually for each
unit. For a successful use of the corrosion-protective agent it is important that it is added to the water in
a mixing ratio of about 1:30 to 1:100. This can be carried out in two ways:
● manually: by refilling it regularly
● automatic dosing: by using an optional dosing device
The corrosion-protective agent and, if required, the dosing device can be ordered directly from the
company Hebro Chemie: tel.: +49 2166 6009 – 0, e-mail: [email protected]
5.3.2. Additive: Defoamer (optional)
The defoamer releases foaming that is produced by certain types of dust. The dust bonds a certain
amount of the defoamer so that it can be necessary to refill some defoamer, depending on the amount
of dust. You can manually add defoamer via the ¾” T-piece (pos. 7) (about 12,5 ml defoamer per 100 l
fresh water). The exact quantity has to be determined via trials. (Defoamer is available on option).
5.4. Installing a water discharge as an overfill protection
The wet separator is equipped with a mechanical overfill protection in order to protect it from too much
water supply (e.g. due to defective magnet valves). When the wet separator exceeds a certain level (B),
the excess water drains off through the opening of the hose (A).
To prevent the water from spilling on the floor in case of overfilling, the operator must install a water
discharge under the opening (A). The water retention can e.g. be done by a hopper. The water
discharge should not be connected directly to the opening (A). Otherwise it might not be possible to
recognize water leakages during a visual inspection.
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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.
CAUTION
Possibility of hazardous dust accumulation.
The operator has to make sure that the upstream processing machine is NOT put into
operation without the cyclone separator! If a fault is detected at the cyclone separator, the
processing ma-chine has to be switched out immediately.
Operating elements for the device control
Representation
Designation
Description / function
Main switch
●OFF: The device is disconnected from the power supply.
●ON: The device is connected to the power supply and
ready to operate.
The main switch also serves as an emergency
off switch.
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.
Button fo manual
water filling
Regardless of the current fluid level, the system can be
filled manually by pressing the button filling. This is
however only possible when the suction unit is not
running. The process is started or stopped when the
button is pressed. When the valve is opened, a visual
feedback is given out by the illuminated push button.
Operating elements for status and error messages
Representation
Designation
Description / function
Signal horn
Honking signals that the unit signals an error. Please refer to
the error message shown on the display of the control.
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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.
All maintenance work must only be carried out in well-ventilated rooms and while wearing an
appropriate protective equipment ! 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 and mud 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. Then disconnect the unit from the power supply by setting the main Switch in
the “OFF” position. 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. Cleaning/replacing: aluminium mesh filter and droplet separator
● Open the service door (see chapter 2.1).
● Detach the grounding cable of the mesh filter and the mist eliminator (see chapter 2.1) from the
housing wall. Therefore detach the protective grid, if necessary (see chapter 2.1).
● Pull the mesh filter and the mist eliminator out of the guide rail. The cleaning can be carried out
with a steam ejector.
If one of the filter elements is too heavily contaminated, it must be replaced
(see list of spare parts). We recommend having filter elements in stock.
● Push the mesh filter and the mist eliminator back into the guide rail.
On reinserting, the grounding cables must be installed again! The
earthing labels indicate where the grounding cables must be connected. Finally, the filter
elements must be checked for electrical grounding at the housing.
● Close the service door.
7.3. Cleaning the mud container
Release the water before cleaning the mud container. In order to reduce the consumption of additives
such as defoamer or especially antifreeze agents (when the wet cyclone separator is placed outside),
the water supply and water outlet should be connected in order to form a closed circuit.
WARNING
Explosion hazard.
The constitution of the shovel must not lead to the production of sparks or to damages at the
surface of the mud container.
During the cleaning operation, there must not be any effective sources of ignition in the
vicinity of the mud container. The maintenance personnel must ensure that static discharges
are avoided during work at the unit. It is also necessary to ensure that there is adequate
ventilation.
● Open the drain cock at the wastewater connection (see chapter 2.1).
● If the deposed mud agglutinates or clumps, the ball valve can choke from time to time.
Therefore it is advisable to control if the ball valve is free in using an appropriate object (e.g. a
stick) before you open the door.
● Open the cleaning flap (see chapter 2.1).
● Remove the remaining mud from the mud container with the help of a shovel.
● The interior of the container is cleaned with the help of an appropriate jet vapour. Please
respect the regulations according to the protection of the environment when cleaning the
container.
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7.4. Maintenance of the magnet valves
The magnet valves (see chapter 2.1) must be regularly checked for their proper functioning.
● Set the wet separator to maintenance condition. For that purpose the power supply for the
control must be maintained, but the fan must be switched off. The door of the control housing
must be opened.
Working at the open control housing involves the risk of electric shock.
The operator must ensure that the maintenance measures are only carried out in the presence
of authorized and qualified personnel.
● Open the cleaning flap (see chapter 2.1).
● Put the maintenance switch in the position “V1”. Now check if water is still flowing in inside the
wet separator.
If water is still flowing in, the magnet valve V1 (see photo) is defective and
must be replaced.
● Put the maintenance switch in the position “V2”. Now check if water is still flowing in inside the
wet separator.
If water is still flowing in, the magnet valve V2 (see photo) is defective and
must be replaced.
● Then put the maintenance switch in the middle, neutral position.
● Close the cleaning flap.
● Close the door of the control housing.
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8. ATEX operation
The following ATEX zoning and ignition source analysis is applied to the filter unit.
8.1. ATEX zoning for WNA-AL
Area
Ex zone
Reason/Cause
Dusts
Gases, vapours, mist
Installation location of
filter unit, spark
separator and controller
No Zone
Installation in areas at risk of explosion not
permitted.
See: Intended use
Zone 2
(in an environment of 5m around
the outlet)
Emission of hydrogen into the installation
premises cannot be definitively excluded.
Suction line between
extraction point and
WNA
Zone 22
Entry of dust via the extraction points /
varying concentration.
Speed of flow in pipe >= 20 m/s, therefore
deposits are avoided in practical terms.
Zone 2
Accumulation of hydrogen cannot be
excluded when stopped.
WNA contact and calm
zone zone
Zone 22
Due to the high level of filtration,
dust bound in water
Zone 2
Accumulation of hydrogen cannot be
excluded when stopped.
WNA clean air zone
No Zone
Due to the high level of efficiency of the
contact zone and of the downstream plate
filter and wire mesh filter, the input of
potentially dangerous quantities of aluminium
dusts and/or magnesium dusts is improbable.
Zone 2
Accumulation of hydrogen cannot be
excluded when stopped
Mud zone / water box
No Zone
Dusts are bound in the water.
Zone 2
Hydrogen may be released when the
container is emptied
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Blower line
No Zone
Penetration of dust is reliably excluded
Zone 2
Emission of hydrogen cannot be definitively
excluded.
8.2. Sources of ignition
If the operator is not able to reliably exclude the possibility of the presence of effective sources of
ignition, such as
a) flames and hot gases
b) mechanically generated sparks
then it is necessary to ensure that the concentration of the dust arising at the extraction point within the
line and the filter unit is always 50% by mass below the lower explosion limit (LEL).
8.2.1. Evaluating the risk of ignition in accordance with DIN EN 80079-36
For the evaluation of the risk of ignition, see the Appendix.
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9. 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.
The operator is obliged to transport, store and dispose of the collected dust and mud in
accordance with national or regional regulations.
10. 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.
Faults indicated by control elements are explained in the chapter “Description of the control
elements”.
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: +49 2541-84841-0
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.
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