AFS 600 Manuel utilisateur

AFS Airfilter Systeme GmbH

Original Instruction Manual for AFS Air Purification

Devices for Removing Oil and Emulsion Mist

O r i g i n a l I n s t r u c t i o n M a n u a l f o r A F S A i r P u r i f i c a t i o n D e v i c e s

f o r R e m o v i n g O i l a n d E m u l s i o n M i st

Produced By:

Version:

Valid from:

U. Burkhardt

1.05

01/11/2016

Neither transfer or reproduction of these documents nor application or disclosure

of their content are permitted without the explicit approval of AFS.

Violations will require compensation for damages. Page 1 of 26

O r i g i n a l I n s t r u c t i o n M a n u a l f o r AF S A i r P u r i f i c a t i o n D e v i c e s

f o r R e m o v i n g O i l a n d E m u l s i o n M i s t

This instruction manual applies to the following AFS air purification devices:

AFS 600, AFS 1100, AFS 1600, AFS 3000, AFS 4000, AFS 6000, AFS 8000, AFS 12000, AFS 16000.

Each classification corresponds to the AFS device's exhaust air output in m

/h.

Inhalt

General Information.............................................................................................................................. 2

1.1

Importance of the Instruction Manual............................................................................................ 3

1.2

Target Audience for the Instruction Manual................................................................................... 3

1.3

Disclaimer .................................................................................................................................... 3

1.4

Appropriate Use............................................................................................................................ 3

1.5

Product Safety.............................................................................................................................. 4

Safety instructions................................................................................................................................. 5

2.1

Danger Due to Unloading and/or Transportation........................................................................... 5

2.2

Danger from Doors and Inspection Doors..................................................................................... 5

2.3

Danger Due to Electrical Power.................................................................................................... 5

2.4

Danger Due to Ventilators............................................................................................................. 5

2.5

Danger from Flaps, Cutoff Devices, or Shutters ............................................................................ 6

Transportation and Loading .................................................................................................................. 6

3.1

Transport Damage and Missing Parts........................................................................................... 6

Design and function of the AFS air purification device........................................................................... 7

4.1

Operating principle ....................................................................................................................... 7

4.2

Design.......................................................................................................................................... 7

Installation and Startup......................................................................................................................... 9

5.1

Device Assembly.......................................................................................................................... 9

5.2

Pipe or Hose Connections............................................................................................................ 9

5.3

Siphon Connections...................................................................................................................... 9

5.4

Electrical Connections.................................................................................................................11

5.4.1

Electrical Connection of AFS Air Purification Device.................................................................11

5.4.2

Motor protection.......................................................................................................................12

5.4.3

Electrical Connection of AFS Air Purification Devices with Frequency Converters (Optional)....12

5.5

Protective Conductor System.......................................................................................................13

5.6

Startup Operations ......................................................................................................................13

Operation.............................................................................................................................................14

6.1

AFS air purification devices without frequency converters............................................................14

6.1.1

Turn on....................................................................................................................................14

6.1.2

Turn off....................................................................................................................................14

6.2

AFS Air Purification Devices with Frequency Converter (Optional)...............................................14

O r i g i n a l I n s t r u c t i o n M a n u a l f o r A F S A i r P u r i f i c a t i o n D e v i c e s

f o r R e m o v i n g O i l a n d E m u l s i o n M i s t

Produced By:

Version:

Valid from:

U. Burkhardt

1.05

01/11/2016

Neither transfer or reproduction of these documents nor application or disclosure

of their content are permitted without the explicit approval of AFS.

Violations will require compensation for damages. Page 2 of 26

6.2.1

Turning the System On:...........................................................................................................14

6.2.2

Switch off the system...............................................................................................................14

6.3

Follow-up time.............................................................................................................................15

6.4

Motor protection: Acknowledge faults...........................................................................................15

Maintenance........................................................................................................................................16

7.1

MaintenanceWork and Cycles for Oil and Emulsion Mist Separation...........................................16

7.1.1

Metal mesh preliminary separator (pos.

•

).............................................................................17

7.1.2

Preliminary filter fleece (pos.

‚

)..............................................................................................17

7.1.3

Longlife separator (pos.

).....................................................................................................18

7.1.4

Post filter H13 (Pos.

„

) ..........................................................................................................19

7.1.5

Metal mesh follow-up separator (pos.

…

)................................................................................20

7.1.6

Ventilator (pos.

†

)..................................................................................................................20

7.1.7

Siphon (pos.

‡

)......................................................................................................................21

7.2

Overview of maintenance intervals...............................................................................................21

7.3

Volumetric flow rate monitoring (optional).....................................................................................23

7.3.1

MPR Functionality....................................................................................................................23

7.3.2

MPR Connections....................................................................................................................24

7.3.3

MPR Error Diagnostics ............................................................................................................24

EG-Konformitäts-Erklärung..................................................................................................................25

Wear parts...........................................................................................................................................26

Explanation of Symbols

Safety precautions, danger point, or important or absolutely mandatory instructions

Electrical connection. Caution: High voltage. Observe safety instructions. Equipment must only

be serviced by a qualified electrician (DIN EN 50 110, IEC 364).

Important additional information or advice for use

1 General Information

AFS Airfilter Systeme GmbH (AFS) manufactures highly efficient mechanical air purification devices and

systems that remove oil, emulsion, and minimal lubricant mist from the air, protecting the workplace

environment in metalworking shops.

Moreover, as a special construction, AFS also manufactures air purification devices for cleaning air

contaminated with solvents in areas that are not at risk of explosion as well as for exhaust air that accrues in

dry processing.

AFS devices are not ATEX-certified!

O r i g i n a l I n s t r u c t i o n M a n u a l f o r A F S A i r P u r i f i c a t i o n D e v i c e s

f o r R e m o v i n g O i l a n d E m u l s i o n M i s t

Produced By:

Version:

Valid from:

U. Burkhardt

1.05

01/11/2016

Neither transfer or reproduction of these documents nor application or disclosure

of their content are permitted without the explicit approval of AFS.

Violations will require compensation for damages. Page 3 of 26

Our AFS air filter systems are today's air purification devices both with respect to their safety levels and

operating safety. By labeling devices with the CE label, we are confirming that the risk and hazard

assessment meets the standards of the valid EC Machinery Directive 2006/42/EC and valid EMC Directive

2014/30/EU; see the EC declaration of conformity appendix.

The type plate, which lists the device type, serial number, and CE mark, is attached to the device’s

door or at the rear of the device.

The relevant norms as well as local, national, and international regulations apply. They are to be

observed and obeyed.

1.1 Importance of the Instruction Manual

Read this instruction manual carefully before installation and startup to ensure proper use!

Please note that this instruction manual only applies to the particular device and not to the

entire system!

The present instruction manual facilitates safe work on and with the device named. It contains safety

information that must be observed as well as information that is necessary for undisturbed operation of the

device.

The instruction manual is to be kept with the device. The instruction manual must be kept available to any

person who is to interact with the device at all times. The instruction manual is to be kept for further use and

must be passed on to each successive owner, user, or end customer.

1.2 Target Audience for the Instruction Manual

The instruction manual is directed at those who are entrusted with planning, installing, operating,

maintaining, or repairing the device and who have thequalifications and knowledge necessary to execute

their activities.

1.3 Disclaimer

This instruction manual has been examined to ensure that its contents coincide with the hardware and

software of the device described. Nonetheless, there may be discrepancies; no guarantee of complete

agreement is implied. We reserve the right to make changes in the construction and technical data in the

interest of further development. Therefore, no claims may be derived from the information, illustrations or

drawings, or descriptions. Errors are excepted.

AFS will not be liable for damages due to incorrect use or inappropriate use or that are incurred as a

consequence of unauthorized repairs or alterations.

1.4 Appropriate Use

AFS air purification devices are intended exclusively for separating and cleaning exhaust air that contains

coolant lubricant from machining tools and centers used in metalworking shops or for the tasks named in the

order confirmation. Any other or additional use that is not contractually agreed upon will be considered

inappropriate. The manufacturer will not be liable for any resulting damages. The company that uses the

device will bear all risk.

Intended use also includes reading this instruction manual and adhering to all of the information contained

therein –particularly the safety information (color code). Instruction manuals for any attached components

O r i g i n a l I n s t r u c t i o n M a n u a l f o r A F S A i r P u r i f i c a t i o n D e v i c e s

f o r R e m o v i n g O i l a n d E m u l s i o n M i s t

Produced By:

Version:

Valid from:

U. Burkhardt

1.05

01/11/2016

Neither transfer or reproduction of these documents nor application or disclosure

of their content are permitted without the explicit approval of AFS.

Violations will require compensation for damages. Page 4 of 26

are also to be observed. The device operator, not the manufacturer, will be responsible for all damages to

persons or property that result from inappropriate use.

1.5 Product Safety

The device was the best available technology at the time of its sale and is regarded as fundamentally

reliable. The device and its accessories may only be installed and operated in sound condition and with due

regard for the installation and operating instructions. Operation outside of the confines of the device's

technical specifications (identification plate and addendum/technical data) may damage the device and could

cause additional damages!

O r i g i n a l I n s t r u c t i o n M a n u a l f o r A F S A i r P u r i f i c a t i o n D e v i c e s

f o r R e m o v i n g O i l a n d E m u l s i o n M i s t

Produced By:

Version:

Valid from:

U. Burkhardt

1.05

01/11/2016

Neither transfer or reproduction of these documents nor application or disclosure

of their content are permitted without the explicit approval of AFS.

Violations will require compensation for damages. Page 5 of 26

2 Safety instructions

2.1 Danger Due to Unloading and/or Transportation

Severe personal injury due to falling:

·Secure the AFS device against tipping and falling.

·Avoid standing under floating loads.

·Secure the assembly area.

2.2 Danger from Doors and Inspection Doors

Low pressure prevails when AFS devices are in operation.

Danger of hand crushing due to pressure from doors and inspection doors on the low-pressure side:

·Open doors only after the ventilator has stopped.

If AFS air purification devices are operated in conjunction with multiple devices, then all of the

devices must be turned off before a door or maintenance door is opened.

2.3 Danger Due to Electrical Power

Danger of electric shock –potentially fatal –from contact with live components:

·Always ensure that there is no electrical power before working.

Danger of electric shock –potentially fatal. Some electric circuits such as the electronics in the

ventilator may be charged for a few minutes after the electrical supply has been interrupted:

·After turning off the electricity, wait at least three minutes before beginning to work

on or near electrical components.

Danger of electric shock due to static charge in the housing:

·Ground the device (see Chapter 5.5).

Danger of electric shock due to short circuit upon contact between electrical components:

·All cables must be examined for assembly damage or

insulation damage before operation.

Danger of electric shock due to wet cleaning the device:

·Always clean without electrical currents.

2.4 Danger Due to Ventilators

After electrical tension has been interrupted, the ventilator can be started up again automatically.

Fatal or severe injury from ventilator rotor:

·Keep persons and objects away from theventilator rotor.

·For all work on the AFS device, switch off power to the system and wait for the ventilator to

stop running.

O r i g i n a l I n s t r u c t i o n M a n u a l f o r A F S A i r P u r i f i c a t i o n D e v i c e s

f o r R e m o v i n g O i l a n d E m u l s i o n M i s t

Produced By:

Version:

Valid from:

U. Burkhardt

1.05

01/11/2016

Neither transfer or reproduction of these documents nor application or disclosure

of their content are permitted without the explicit approval of AFS.

Violations will require compensation for damages. Page 6 of 26

Fatal or severe injury from the ventilator's suction effect on clothing and hair:

·Never wear loose clothing and tie up long hair.

·For all work on the AFS device, switch off power to the system and wait for the ventilator to

stop running.

Fatal or severe injury from rotor bursting if the maximum permissible operating speed is exceeded:

·Always operate the ventilator within permissible operating speed range.

·For all work on the AFS device, switch off power to the system and wait for the ventilator to

stop running.

2.5 Danger from Flaps, Cutoff Devices, or Shutters

Flaps, cutoff devices, or shutters may be built into the pipes or ducts leading to or from the AFS air

purification device.

Danger of finger crushing due to the motion of a shut-off flap:

·Keep hands away from the flap area.

Danger of hand injuries due to closing shutter flaps:

·Keep hands away from the flap area.

3 Transportation and Loading

The devices are delivered on non-returnable pallets and may be recycled by the recipient.

All other components are delivered in recyclable non-returnable packaging to be recycled by the recipient.

The devices can be transported and moved using a forklift (by lifting the entire transport pallet with the

device) or, if they are fitted with lifting eyes, lifted off the pallet using transport chains.

AFS devices may only be transported, loaded, or handled by qualified personnel with appropriate

professional qualifications.

3.1 Transport Damage and Missing Parts

Please check the delivery for completeness using the delivery documents / part lists as a reference and

check the device for transport damage in the presence of the forwarder immediately on receipt. If there are

any damaged or missing parts, please take a written note of this, let the forwarder countersign this note, and

immediately notify the respective transport company and AFS, in the case of

Visible damage: Immediately, i.e. without undue delay.

Hidden damage: Within one week.

O r i g i n a l I n s t r u c t i o n M a n u a l f o r A F S A i r P u r i f i c a t i o n D e v i c e s

f o r R e m o v i n g O i l a n d E m u l s i o n M i s t

Produced By:

Version:

Valid from:

U. Burkhardt

1.05

01/11/2016

Neither transfer or reproduction of these documents nor application or disclosure

of their content are permitted without the explicit approval of AFS.

Violations will require compensation for damages. Page 7 of 26

4 Design and function of the AFS air purification device

The operating principles and basic structure of all AFS air purification devices are the same; they differ

only in scale, ventilation system performance, airflow direction, number of filters used per cross-sectional

area (regardless of device type), color and layout of attachments.

4.1 Operating principle

Aerosols and particles from the coolant lubricant in the machine exhaust air are separated from/filtered out of

the air current in the AFS air purification device.

The separated coolant lubricant accumulates in the bottom area of the air purification device and drains

through the two siphon lines.

The suction output is generated by a motor fan wheel. The motor fan wheel is located in the airflow direction

after the post filter and thus on the clean gas side.

4.2 Design

Figure 1: Exemplary design and component description using an AFS 100 with suction left as an example.

1 Suction on all sides of the device possible

2 Housing

3 Exhaust vent

4 Installation space for motor fan wheel

5 H13 filter or metal mesh follow-up separator

6 Maintenance opening (doors)

7 Hose or pipe connection

O r i g i n a l I n s t r u c t i o n M a n u a l f o r A F S A i r P u r i f i c a t i o n D e v i c e s

f o r R e m o v i n g O i l a n d E m u l s i o n M i s t

Produced By:

Version:

Valid from:

U. Burkhardt

1.05

01/11/2016

Neither transfer or reproduction of these documents nor application or disclosure

of their content are permitted without the explicit approval of AFS.

Violations will require compensation for damages. Page 8 of 26

Figure 2: Exemplary description of material flows as well as separator and filter stages using the AFS 1600 as an

example

A polluted machine exhaust air

B purified exhaust air

C separated coolant lubricant/condensate

1 5-stage preliminary separation

2 Follow-up separator

Figure 3: Elements of the preliminary separation in AFS air purification devices

1 Metal mesh preliminary separator

2 Filter fleece (depicted without alternate frames)

3 Longlife separator

O r i g i n a l I n s t r u c t i o n M a n u a l f o r A F S A i r P u r i f i c a t i o n D e v i c e s

f o r R e m o v i n g O i l a n d E m u l s i o n M i s t

Produced By:

Version:

Valid from:

U. Burkhardt

1.05

01/11/2016

Neither transfer or reproduction of these documents nor application or disclosure

of their content are permitted without the explicit approval of AFS.

Violations will require compensation for damages. Page 9 of 26

5 Installation and Startup

5.1 Device Assembly

The device must always be set up horizontally on a rigid and, if possible, vibration isolated base.

The minimum distances between the device and ceilings, walls etc. required to ensure proper operation are:

Top of the device (exhaust air outlet): > 800 mm

Motor side: > 500 mm

Door side: > 800 mm

Bottom of the device (siphon connection): > 500 mm

These minimum distances must be observed to ensure that the device can operate properly.

5.2 Pipe or Hose Connections

Devices for connecting suction pipes or hoses must be arranged as follows:

§Kink-free

§Large bending radius (radius ³diameter)

§About 3° slope toward the air purification device or suction point

§No water pockets or sagging pipes

§If low points are unavoidable, for instance in passages that run below girders, the lowest point is to

be equipped with a condensate drain with a siphon outflow.

The extraction opening on your processing machines should be fitted with a baffle plate to prevent droplets

of coolant lubricant from entering the pipe:

§There should be a ca. 100 mm gap between this opening and the wall

§The cover over the extraction opening should be at least 100 mm on all sides

§The surface of the annular passage should be at least as large as the cross-sectional area of the

suction pipe.

5.3 Siphon Connections

Two ½“outlets (three outlets for AFS 12000 and AFS 16000) are located on the bottom of the device for

draining the coolant lubricant.

A siphon connection must be installed at each opening and filled with coolant lubricant.

The siphon lines must lead to a collection container or a collecting pipe.

The following points must always be observed. Otherwise the device will no longer function

properly.

§Siphon design as a U pipe or loop based on Figure 4.

§The distance between the bottom of the device and the top siphon loop must be:

·At AFS devices 600-1600 at least 200 mm

·At AFS devices 3000-16000 at least 250 mm

§The height of the loop or U pipe must be:

·At AFS devices 600-1600 at least 200 mm

·At AFS devices 3000-16000 at least 250 mm

§The pipe must point downward in the direction of the collection container or collecting pipe.

§No low points or water pockets.

§Each siphon opening must be connected separately.

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