Teka FilterCube 4-IFA Manuel utilisateur

Operating instructions

(Translation of the original operating instructions)

FilterCube 4 - IFA

TEKA Absaug- und Entsorgungstechnologie GmbH, Millenkamp 9, D-48653 Coesfeld,

Tel.: +49 2541-84841-0, E-Mail: info@teka.eu, www.teka.eu

Table of contents

1. General 3

2. Description of the system elements 4

2.1. Illustration of the system elements 4

2.2. Functionality of the system 4

2.3. Intended use 5

2.4. Residual risk 5

3. Safety instructions 5

3.1. Definition of the hazard symbols 5

3.2. General safety instructions 6

4. Storage, transport and installation of the device 7

5. Commissioning 8

5.1. Connecting the suction line and exhaust air line 9

5.2. Electrical connection 10

5.3. Precoating of the filter cartridges 11

5.4. Connecting the compressed air supply 11

5.4.1. Compressed air supply for the cleaning of the filter cartridges 11

6. Operating the system 12

6.1. Explanation of the operating elements 12

7. Maintenance 13

7.1 Reset to maintenance state 14

7.2. Cleaning the filter cartridges 15

7.3. Replacing the filter cartridges 16

7.4. Emptying the dust collecting tank 22

7.5. Draining the condensate 23

7.6. Precoating of new filter cartridges 24

7.6.1. Feeding the precoat via a FVS (TEKA spark pre-separator) 25

7.7. Cleaning/replacing the particle sensor 26

7.8. Replacing the filter mats at the control cabinet 27

8. Dismantling / Disposal 28

9. Diagnostics and troubleshooting 28

10. List of spare parts 30

11. Technical data 31

12. EC declaration of conformity 32

13. Training protocol 33

14. Maintenance intervals 34

14.1. Usage-related maintenance 34

14.2. General maintenance 35

14.2.1. Visual inspection of the device 35

14.2.2. Visual inspection of the pipelines for dust deposits 36

14.2.3. Visual inspection of the pneumatic pipes 36

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14.2.4. Functional test of the device 36

14.2.5. Electrical test of the electrical lines and earthing connections 37

14.2.6. Test of fixing of the mounted unit elements 37

1. General

Congratulations on purchasing the product from TEKA.

Our engineers ensure that our devices reflect the state of the art through continuous development.

Nevertheless, misuse or misconduct can endanger your safety. Please observe the following for a

successful use of the device:

Only authorised and instructed personnel can carry out transport, operation,

maintenance and repair of the device. The operator must ensure that the operating

personnel take note of these instructions.

Please read these instructions before operating the device, and observe the safety

precautions to avoid injury!

Store this manual in a safe place! These instructions are to be regarded as a component

of the product!

Adhere to all product notes!

Modifications or conversions that the operator carries out at the device without the

consent of the manufacturer, can lead to new safety hazards or to the loss of warranty

claims.

Observe the manufacturer’s instructions. Contact the manufacturer in case of any

uncertainty:

Tel: +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. 21382701

Pos.1

Pos.2

Pos.3

Pos.4

Dust collecting housing

Filter housing

Cleaning housing

Fan

Pos.5

Pos.6

Pos.7

Pos.8

Pos.9

Suction nozzle

Exhaust air nozzle

Connection for compressed air

Drain valve for compressed air

Silencer

2.2. Functionality of the system

The filter unit serves to suck off and filter polluted air (according to the intended use). The air is purified

on the surface of the filter cartridge in the filter section of the unit. The separated dust is collected in a

dust collecting tank. An automatic filter monitoring indicates when a cleaning or a replacement of the

filters is necessary. The purified air is led outside via the exhaust air pipe or back into the working room.

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2.3. Intended use

The device is intended for commercial use. If the device is made publicly accessible, it must never be

operated unsupervised by authorized personnel, authorized by the operator.

The filter unit is intended for extraction and filtration of dusts and fumes that result from thermal joining

and cutting of metals. The filter unit is amongst others suitable for separating welding smokes of

unalloyed and alloyed steels as well as of high-alloy chromium-nickel steels and therefore meets the

highest welding fume separation category “W3” according to DIN EN ISO 21904-1 / -2.

WARNING

Improper use can damage parts and be a danger to life and limb!

The device must not be used for the extraction of oil-laden welding fume, explosive dust

and gases, hybrid mixtures, glowing or burning substances, gases, water, etc. The

device must not be operated in explosive zones.

Dangers arising from fire.

If the sucked medium is combustible fume or dust, the operator must determine

beforehand which fire protection measures are to be taken.

2.4. Residual risk

CAUTION

Danger due to possible hazardous materials in the exhaust air flow.

Because the unit does not monitor the quality of the air in the exhaust air flow, we

recommend that you always guide the exhaust air flow exiting our unit to areas (e.g. to the

outside into the open air) in which there is no danger to any living being. To do this, it is

necessary to fit a suitable exhaust air line at the filter unit.

3. Safety instructions

3.1. Definition of the hazard symbols

The device is constructed according to the state of the art and the recognised safety regulations.

Nevertheless, during use threats to life and limb of the user or other persons may arise. The impairment

of the machine or other property are also possible. In these instructions we warn by using corresponding

indications.

WARNING

These instructions are made in case of risks that can lead to injury or death.

CAUTION

These instructions are made in case of risks that can lead to injury.

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NOTICE

These instructions are made in case of risks that can lead to material damages.

Information notes are no hazard warnings; they call attention to useful information.

3.2. General safety instructions

WARNING

Dangers arising from improper use / unauthorised operations.

The operator must ensure that their authorised personnel are familiar with all the safety

indications in this manual in advance. The operator is responsible for ensuring that all work

is carried out by authorised and qualified personnel. We therefore recommend using the

training protocol on the last page for that purpose (see chapter “Training protocol”).

Laymen are allowed to operate the device after having received the necessary instructions.

But they are not allowed to carry out any installation, repair or maintenance work.

Dangers arising from fire.

In case of fire, if possible, switch the unit immediately off or disconnect it from the power

supply. Fire extinguishing measures which the operator is obliged to determine beforehand

must be initiated immediately.

WARNING

Dangers arising from electricity.

The operator must ensure that electrical plants and equipment are only built, modified and

maintained by a qualified electrician or under the direction and supervision of a qualified

electrician. Do not work on components if you are not sure that these are disconnected. If

necessary, disconnect the device from the electric power supply and secure it against

unauthorized restarting.

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4. Storage, transport and installation of the device

WARNING

Risk of injury from tilting or unmounted components when stored or transported.

The device must be secured against tilting and slipping when it is stored or transported. Do

not stand under or next to the floating load. Lift trucks, forklift trucks and transport cranes

must have a sufficient minimum load bearing capacity.

Dangers arising from titling or functional impairments at its destination.

The unit may only be set up on a suitable surface. The unit may only be set up on a suitable

surface. The surface must be vibration-free and horizontal. The operator must check the

bearing capacity of the surface. The unit must be secured on the surface, for example using

lag bolts or stud bolts.

NOTICE

Damage or functional impairment of the unit due to climatic influences.

The unit must be stored in a dry place and protected against moisture during transport. As a

matter of principle, the filter unit is not designed to be installed outdoors. In this case contact

the manufacturer in order to find out if a caping or a trace heating system are necessary.

● First the filter unit as delivered must be transported to its destination. There the filter unit must

be moved to an upright position. Therefore, lift the filter unit with lifting tools:

Unit type 1 (with sound insulation housing): Use the 4 lifting rings (A).

Unit type 2 (without sound insulation housing): Use the 4 lifting rings (B) at the fan housing.

Unit type 3 (with fan attached alongside): Use the lifting rings (C) for the filter unit. You can

move the fan by lifting it with fork lift forks underneath the bottom (D) of the fan.

Use appropriate lifting tools (forklift truck, transport crane,...) with a

minimum load-carrying capacity of 1000 kg. The filter unit must be secured against tilting

and slipping when it is moved, lifted or put down. No one is allowed to stand under or

beside the load. Use only appropriate ladder tools.

● For setting up the filter unit at its precise designated position, you can use the methods

mentioned for each unit type. When the mentioned method is used, it may only be transported a

short distance. The filter unit must be set up and fixed on a suitable surface.

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5. Commissioning

WARNING

Dangers arising from a defective condition of the unit.

Make sure that the measures described in this chapter are completed before the

commissioning of the unit. All doors of the unit must be closed and all necessary connections

must be attached before turning the unit on. Do not operate the unit if any components are

defective, missing or damaged. Check the orderly condition of the unit before switching it on.

The unit must not be operated without a filter element.

NOTICE

Damaged supply lines.

Make sure that the supply lines are protected against damage by forklift trucks and similar

events. Protect all supply lines from heat, moisture, oil and sharp edges.

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5.1. Connecting the suction line and exhaust air line

For extracting the contaminated air, a suction line must be connected to the suction nozzle (see chapter

2.1).

CAUTION

Danger for the respiratory tract arising from polluted ambient air. Dust deposits in the

suction pipe are possible.

Only operate the system if the necessary suction line is fitted. The suction line must be

dimensioned according to the application in such a way that, if possible, no dust deposits

occur in the suction line. If this has not already been carried out by TEKA, a suitably qualified

employee must be consulted. If the suction line includes extraction elements (e.g. suction

arms, pipe grills, etc.), these must also be included in the layout. If this is the case then users

must be informed of whether extraction elements can be used simultaneously and, if this is

possible, then which. The regulating devices (e.g. throttle valves) of each single extraction

element must also be set appropriately during the final commissioning.

Depending on the application, the suction pipe must be equipped with extraction elements (suction arm,

extraction hose, round duct grille, etc.). When using a capture element with an extractor cowl, the

extractor cowl must follow the weld seam, if possible by using the movement of the welding fume

caused be thermal influences.

You have to make sure that connections between the workpiece and the suction

hood (and in general between the workpiece and the filter unit) are avoided in order to prevent

the welding current from flowing back to the welding machine via the protective conductor of the

filter unit.

If the air shall be directly sucked off by an upstream machine, the suction line must be connected to the

capture opening of the upstream machine.

The exhaust air pipe must be attached to the exhaust nozzle (see chapter 2.1).

In the case of an optional fan housing standing alongside, the filter unit and the fan must be connected

by means of a connecting pipe.

WARNING

Danger to life when reaching the fan impeller.

The exhaust air pipe must be attached before the commissioning.

If no exhaust air pipe is attached, the protective grille of the silencer must be installed.

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5.2. Electrical connection

WARNING

Risk of electric shock.

Electrical plants and equipment may only be built, modified and maintained by a qualified

electrician or under the direction and supervision of a qualified electrician. Do not work on

live electrical components and elements if you are not sure that these are indeed

disconnected. If necessary, disconnect the device from the mains. The operator is

responsible for a potential-free balance of the equipment.

If the unit is equipped with a frequency converter, then it may only be operated on networks

with an AC/DC sensitive RCCB. For frequency converter operation, the cross section of the

protective conductor

● must be at least 10mm²,

● and must be at least equal to the size of the operator side outer conductor

cross-section.

CAUTION

Health hazard arising from unintentional cleaning processes.

Switch on the control only if the unit is in operational condition.

NOTICE

Electric malfunction possible in cause of an incorrect power supply.

Pay attention to the admissible supply voltage. Please observe the specifications on the type

plate.

● Mount the housing of the external control (if it is not mounted on the device itself) close to the

device on the wall or at any other appropriate mounting point. Or mount the control together

with a cabinet console on a suitable surface, for example using lag bolts or heavy-duty anchors.

The housing is not suited for outdoor installation.

● Connect all visible cables and hoses are according to their functions. When delivered they are

labelled according to their functions. When connecting to the control, please observe the

specifications on the circuit diagram which is attached to the control.

● Connect the unit to the power supply.

● Check if the direction of fan rotation is correct (This is not necessary in the case of units with a

frequency converter). A wrong rotation direction can be identified thanks to the sticker sticked to

the fan scroll which is showing the direction. Compare the rotation direction on the sticker to the

rotation direction of the motor cooling fan when the motor is running down after being switched

off. If the motor rotates in the wrong direction, disconnect the device from the power supply and

exchange two phases at the supply line to the control.

When the fan rotates in the wrong direction, the extraction capacity is

reduced.

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