Teka WNA User manual

Operating instructions
(Translation of the original operating instructions)
Wet separator
version “WNA”
TEKA Absaug- und Entsorgungstechnologie GmbH, Millenkamp 9, D-48653 Coesfeld,
Tel.: [phone], E-Mail: [e-mail],www.teka.eu
1

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 9
5.2. Electrical connection 10
5.3. Water supply / water quality 11
5.3.1. Additive: corrosion protection "hebro®protect 95-103" (optional) 12
5.3.2. Additive: Defoamer (optional) 12
5.4. Installing a water discharge as an overfill protection 12
6. Operating the system 13
6.1. Explanation of the operating elements 13
7. Maintenance 14
7.1. Reset to maintenance state 14
7.2. Cleaning/replacing: aluminium mesh filter and droplet separator 15
7.3. Cleaning the mud container 15
7.4. Maintenance of the magnet valves 16
8. Dismantling / Disposal 17
9. Diagnostics and troubleshooting 17
10. List of spare parts 18
11. Technical data 19
12. EC declaration of conformity 20
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13. Training protocol 21
14. Maintenance intervals 22
14.1. Usage-related maintenance 22
14.2. General maintenance 22
14.2.1. Visual inspection of the device 23
14.2.2. Visual inspection of the pipelines for dust deposits 23
14.2.3. Functional test of the device 24
14.2.4. Electrical test of the electrical lines and earthing connections 24
14.2.5. Test of fixing of the mounted unit elements 24
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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. 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 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 grinding dusts.
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, etc. The device must not be operated in explosive zones.
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 lifting 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.
● 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.
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.
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.
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.
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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.
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.: [phone] – 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.
Operating elements for the device control
Representa
tion
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
Representa
tion
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 respiratory mask! We recommend: respiratory
protection half mask DIN EN 141/143 protection level P3. 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 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.
● 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. 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 store and dispose of the collected dust in accordance with national or
regional regulations.
9. 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: [phone]
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.
The motor rotates in the wrong
direction.
The rotating field of mains
connection point must be
changed.
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Suction line contracted.
Check and fix.
Exhaust line contracted.
Check and fix.
Maybe throttle valves are used in the
suction line.
Adjust throttle valves.
The system is very noisy.
The motor rotates in the wrong
direction.
The rotating field of mains
connection point must be
changed.
There is no silencer mounted.
Mount the silencer.
The suction line or exhaust line are not
mounted.
Mount the line.
The unit is untight.
Check and fix.
10. List of spare parts
Filter element
Article no.
Aluminium mesh filter:
(2 pieces of these filter elements are required for the device)
- WNA 1500
- WNA 2000 / WNA 3000 / WNA 3500
- WNA 5000
- WNA 7500
- WNA 9000
200351500
200353500
200355000
200357500
200359000
Droplet separator:
(2 pieces of these filter elements are required for the device)
- WNA 1500
- WNA 2000 / WNA 3000 / WNA 3500
- WNA 5000
- WNA 7500
- WNA 9000
20007064702xxxx
20005441706xxxx
20003061201xxxx
20006385705xxxx
20011102505xxxx
Other parts
Article no.
Magnet valve, 24 V DC
9501420002
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11. Technical data
Version
1500
2000
3000
3500
5000
7500
9000
Supply voltage
V
400
Frequency
Hz
50
Type of current
Ph
3
Current intake
A
3,5
5,0
6,6
8,5
11,5
15,5
20,4
Air flow volume
(possible operation point)
m³/h
1500
2000
2400
2900
5000
6500
8000
Negative pressure
(possible operation point)
Pa
2400
2400
3000
3200
2600
2700
2700
Protection class
IP54
ISO class
F
Width
Depth
Height
mm
mm
mm
850
1160
2660
1050
1360
2575
1050
1360
2625
1050
1360
2635
1250
1560
3220
1450
1760
3285
1550
1760
3320
Sound pressure level
dB(A)
74
Allowed ambient
temperature
°C
+5 to +35 (during operations)
-10 to +40 (during transport and storage)
Allowed max. humidity
%
70
Weight (without water filling)
kg
ca. 450
ca. 600
ca. 600
ca. 600
ca. 650
ca. 750
ca. 800
Water filling during operation
L
ca. 130
ca. 180
ca. 180
ca. 180
ca. 280
ca. 380
ca. 450
Water consumption per hour
(The water consumption is
dependent on flow velocity, air
temperature, etc. Therefore it can
vary due to the operating conditions.)
L
ca. 4
ca. 5
ca. 6
ca. 7
ca. 10
ca. 15
ca. 18
Water supply
Hose nozzle ¾“
Required water pressure
min./max.
bar
0,3 / 16
Extraction performance
%
> 80
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12. EC declaration of conformity
according to the Machinery Directive 2006/42/EG, Annex II, 1 A
TEKA Absaug- und Entsorgungstechnologie GmbH
Millenkamp 9, D-48653 Coesfeld
Tel.:[phone] E-Mail: [email protected] Internet: www.teka.eu
Designation of the device: TEKA wet separator WNA
We hereby declare under our sole responsibility that the product mentioned above, from the serial
number A19400010011001 resp. P44000010011001 on, conforms to the following directives:
Machinery Directive: 2006/42/EG
Electromagnetic Compatibility: 2014/30/EC
This declaration will become void if the device is exposed to modifications that are not approved by the
manufacturer in written form.
Authorized representative for the technical documentation:
TEKA Absaug- und Entsorgungstechnologie GmbH, Millenkamp 9, D-48653 Coesfeld
(Jürgen Kemper, managing director)
Coesfeld, 3rd january 2021
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