Operating instructions

Operating instructions (Translation of the original operating instructions) Type TEKA FILTERCUBE-MV TEKA Absaug- und Entsorgungstechnologie GmbH Industriestraße 13 D-46342 Velen Postfach 1137 D-46334 Velen Tel.: +49 (0) 2863 9282-0 Fax: +49 (0) 2863 9282-72 email: sales@teka.eu www.teka.eu

Contents 1 Drawing / description of the elements 3 2 Preface 4 3 Operation TEKA FILTERCUBE-MV 5 4 Safety instructions 5 5 Commissioning 7 5.1 Extraction and outlet air piping 7 5.2 Connecting the compressed air supply 7 5.3 Connecting the device 7 6 Maintenance 8 6.1 Dedusting the filter cartridges 8 6.2 Compressed air supply 9 6.3 Emptying the dust container 9 6.4 Releasing the condensate 10 6.5 Replacing the filter cartridges 11 6.6 Relubricating the fan 11 7 Disposal 12 8 Control of the device 12 9 List of spare parts 12 10 Technical data 13 11 Declaration of conformity for TEKA-Filtercube-MV 14 BA_Filtercube-MV_120613_GB.doc 2 13.06.2012

1 Drawing / description of the elements Pos.1 Pos.2 Pos.3 Pos.4 Pos.5 Pos.6 Pos.7 Pos.8 Pos.9 Pos.10 Pos.12 Pos.13 Pos.14 Cover Fan housing Maintenance door for the fan Intermediate cover Dedusting housing Maintenance door for pneumatics Filter housing Maintenance door for cartridges Dust housing Maintenance door for container Chute Dust container Snap fastener Pos.15 Pos.16 Pos.17 Pos.18 Pos.19 Pos.20 Pos.21 Pos.22 Pos.23 Pos.24 Pos.25 Pos.26 Suction nozzle Outlet nozzle Filter cartridge Cartridge bracket Locking screw for filter cartridge Compressed air container Compressed air connection Discharge cock for condensate Control unit Main switch ON/OFF Emergency stop button Mains cable with mains plug BA_Filtercube-MV_120613_GB.doc 3 13.06.2012

2 Preface In the course of the last years, extraction units have become more and more important, especially the filtration of extracted pollutants and the return of the filtered air into the working space. This certainly shows that the individual s environmental awareness has strongly developed in a positive way since the fact that production (e.g. welding) generates pollutants is undoubted for a long time. The types of pollutants however depend on the applied procedure. Generally, you distinguish gases from fumes. Fumes are also known as dusts. If you examine these dusts with a microscope, you will state that they consist of tiny respirable particles of 0,001 mm or even smaller sizes. The conventional attempt to improve working conditions at polluted work places is general aeration. This procedure is based on a multiple exchange of the air in the production hall, in other words the complete air is renewed. Nevertheless, this method only reduces the concentration of pollutants in the respiration zone of the user to a minimal extent. This also applies for the so-called overhead extraction, i.e. the installation of huge extraction hoods above the workplaces. With this insufficiently realized airflow, the pollutants pass by the breathing zone of the user before they rise up and are taken in and extracted. This certainly is not the intended effect. More efficient than room exhausting or overhead extraction is the elimination of pollutants directly at their source in using local extraction. The investments as well as the operating expenses are much lower in case of local extraction. The successful application of this technology implies the technological optimization of the working procedure and especially respecting measures with regard to environmental protection and occupational safety. In the context of a growing awareness and stricter legal regulations, potential hazards for the environment and the workplace have to be determined prematurely and minimized if necessary. BA_Filtercube-MV_120613_GB.doc 4 13.06.2012

3 Operation TEKA FILTERCUBE-MV The filter unit TEKA - FILTERCUBE-MV is mainly used to extract dusts and fumes. To this end, the unit has to be equipped with extraction devices adapted to the application. Prohibition of use: Welding fumes containing oil, aluminum dust, gases, water, etc. (If in doubt, please contact the manufacturer!) The polluted air is extracted by the extraction device and enters the filter unit passing the suction hose or the piping. This is where the polluted particles are separated on the surface of the integrated filter cartridge. The cleaned air is taken in by the fan and returned outside or into the working space via an adapted outlet piping. As soon as the resistance of the filter cartridge has reached a maximum value due to the separated dust particles or after a set idle time has expired, the filter are automatically dedusted. Due to the integrated pneumatic dedusting, the compressed air is evenly distributed over the filter surface, which releases the accumulation of dust. (see chapter 6.1: Dedusting the filter cartridges The released dust is collected in a dust container where it can be extracted. (see chapter 6.3: Emptying the dust container ) 4 Safety instructions When handling electrical appliances, the following general safety measures must be taken for the protection against electric shocks, risk of injury and fire: Read and observe these instructions before using the device! Keep this operating and maintenance manual in a safe place! Do not use the device to extract inflammable or explosive gases and/or dust mixtures! Do not use the device in explosive zones, e.g. zone 0, zone 1, zone 2, zone 20, zone 21, zone 22! Do not use the device to extract burning or glowing materials, e.g. cigarettes, matches, metallic dusts or splinters, paper, cleaning cloths, etc.! Do not use the device to extract burning or inflammable materials, e.g. oil or oil mist, grease, release agents (e.g. silicone spray), cleaning agents, etc.! Do not use the device to extract aggressive media! Do not use the device to extract burning or glowing substances! Do not use the device to extract liquids of all kind! Do not use the device to extract organic materials without a written authorization of the manufacturer! Protect the connection plug from heat, humidity, oil and sharp edges! Observe the admissible supply voltage! (Observe the indications on the nameplate!) Only use TEKA spare parts! Do not use the device without a filter element! BA_Filtercube-MV_120613_GB.doc 5 13.06.2012

Disconnect the filter unit from the mains supply before opening the device! Empty the compressed air container before performing any kind of maintenance or repair task. The outlet opening must not be covered or blocked! Always make sure that the device is in a safe position! Use the attached eye hooks to transport the device! When transporting the device, make sure that no person remains under the device! When cleaning and maintaining the device, when replacing parts or when changing to another function, disconnect the filter unit from the mains supply! Dispose of the filter cartridges according to the legal regulations. Check the control lines of the suction crane regularly regarding signs of damage. The device must not be used if the mains line is not in a perfect condition. Only use dry and oil free compressed air and an operating pressure of 4 bar minimum and 6 bars maximum. Do not use the filter unit if one or more parts of the unit are faulty, missing or damaged. In every of these cases, please contact the TEKA service department at the phone number +49 28 63 92 82 0. When extracting carcinogenic welding fume, e.g. materials containing nickel or chrome, the ventilation requirements of the TRGS 560 (Air return during handling of carcinogenic hazardous substances) have to be observed! For further information concerning TRGS 560, please contact the German Institute for Occupational Safety and Health (BIA) in 53754 Sankt Augustin. BA_Filtercube-MV_120613_GB.doc 6 13.06.2012

5 Commissioning The filter unit is fully wired. Extraction elements, outlet air/ circulating air piping and other accessories if necessary have to be connected or installed before commissioning. The filter unit is switched ON and OFF via the main switch (pos. 24). 5.1 Extraction and outlet air piping The extraction elements must be fixed to the suction nozzle (pos. 15) with the help of an extraction piping. The outlet/ circulating air piping must be fixed to the outlet nozzle (pos. 16). 5.2 Connecting the compressed air supply External supply is only admissible with an approved compressed air hose! Connect the compressed air hose to the compressed air connection (pos. 21) with the help of a hose coupling. The supplied operating pressure must be 4 bar minimum and 6 bar maximum. Empty the compressed air container before performing any kind of maintenance or repair task. In case of leakage of the pneumatic device, the filter unit may not be put into operation any more. Without compressed air supply, the filter cartridge pollutes very fast and the device indicates a fault. 5.3 Connecting the device Connect the control unit to the mains supply. (Observe the indications on the nameplate!) Only electricians are authorized to perform tasks regarding electric connections! Observe indications on the nameplate! 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 BA_Filtercube-MV_120613_GB.doc 7 13.06.2012

6 Maintenance Due to the filtration of dust particles, the saturation degree of the filter cartridge increases and the extraction performance is reduced. The filter cartridges are dedusted controlled by differential pressure or time. (see chapter 6.1: Dedusting the filter cartridges The dust particles are blown off downstream from the inside to the outside. The released accumulation of dust falls into the dust container intended for this purpose. (see chapter 6.3: Emptying the dust container The lifetime of the filter cartridges depends on the conditions of application. That is why it cannot be defined beforehand. If the filter cartridges cannot be dedusted any more, they have to be replaced. (see chapter 6.5: Replacing the filter cartridges ) The filter unit TEKA FILTERCUBE-MV is either equipped with a 5,5 kw or a 11 kw turbine. In case of an 11 kw turbine, the bearings have to be relubricated after expiration of a certain amount of operating hours. (see chapter 6.6: Relubricating the turbine ) While changing the filter cartridge, the operation of the filter unit has to be interrupted. Empty the compressed air container before performing any kind of maintenance or repair task. Only change and dispose of filter cartridges in sufficiently ventilated spaces and wearing an adapted respirator mask! We recommend: Respirator half masks according to DIN EN 141/143 protection level P3. Only a sufficiently instructed employee is authorized to replace the filter cartridge! 6.1 Dedusting the filter cartridges The filter unit remains in operation during the automatic dedusting process. p control: In order to maintain the admissible extraction performance of the device, the saturation degree of the filter cartridges (pos. 17) is monitored electronically. If the set differential pressure is exceeded, the filter cartridges are automatically dedusted until the set threshold value is reached. Time control: If the dedusting process is time-controlled, the filter cartridges are dedusted within a set time interval, independent from the pressure. See corresponding instruction manual for further information concerning settings and functions of the control modes. (see chapter 8: Control of the device ) Without compressed air supply, the filter cartridge pollutes very fast and the extraction performance is reduced. BA_Filtercube-MV_120613_GB.doc 8 13.06.2012

6.2 Compressed air supply For a trouble-free operation of the device, the compressed air supply has to be in perfect condition. The compressed air must be dry and oil free. The produced condensate in the compressed air container (pos. 20) has to be emptied regularly. (see chapter 6.4: Releasing the condensate ) If you use an upstream water separator (available as an option), it must also be controlled regularly and emptied if necessary. The pneumatic parts of the device have to be regularly checked for leakages. The external supply must be connected with an approved compressed air hose and an operational pressure of 4 bar minimum and 6 bar maximum. A compressed air container of 15 litres is integrated as a reserve. The content is sufficient for one dedusting process. After completion of the dedusting process, compressed air is immediately refilled for the next dedusting interval. Empty the compressed air container before performing any kind of maintenance or repair task. In case of leakage of the pneumatic device, the filter unit may not be put into operation any more. Without compressed air supply, the filter cartridge pollutes very fast and the extraction performance is reduced. 6.3 Emptying the dust container The dust container (pos. 13) has to be cleaned after expiration of a certain amount of operating hours. The amount of hours depends on the quantity of dust produced. Disconnect the control unit for the dedusting from the mains supply for the dedusting. (In case of a p control, wait for the set dedusting intervals.) Open the maintenance door for the container (pos. 10). Open and unhook the snap fasteners (pos. 14) about 5 minutes after completion of the last dedusting. Withdraw the dust container (pos. 13) from the housing for the dust collection (pos. 9). Store or dispose of the accumulated dust in an appropriate container according to the regulations. Push the dust container (pos. 13) into the housing for the dust collection (pos. 9). BA_Filtercube-MV_120613_GB.doc 9 13.06.2012

Fix and close the snap fasteners (pos. 14), so that the container (pos. 13) seals tightly below the chute (pos. 12) of the filter unit. (When doing this, check the sealing below the chute (pos. 8) for damages and replace it if necessary.) Connect the control unit for the dedusting to the mains supply. (Observe the indications on the nameplate!) Only empty the dust container in sufficiently ventilated spaces and wearing an adapted respirator mask! Empty the compressed air container before performing any kind of maintenance or repair task. We recommend: Respirator half mask according to DIN EN 141/143 protection level P3. Only a sufficiently instructed employee is authorized to perform the steps mentioned above! Dispose of the filter cartridges according to the legal regulations. 6.4 Releasing the condensate The produced condensate in the compressed air container (pos. 20) has to be emptied regularly. Disconnect the control unit from the mains supply for the dedusting. Disconnect the compressed air container from the external compressed air supply. Open the discharge cock (pos.22) and fill the condensate into an appropriate container. (When opening the discharge cock, the compressed air stored in the compressed air container (pos. 20) escapes.) Store or dispose of the accumulated dust in an appropriate container according to the regulations. Close the discharge cock (pos. 22). Connect the compressed air container to the external compressed air supply. Connect the control unit for the dedusting to the mains supply. (Observe the indications on the nameplate!) Only a sufficiently instructed employee is authorized to perform the steps mentioned above! Dispose of the condensate according to the legal regulations. BA_Filtercube-MV_120613_GB.doc 10 13.06.2012

6.5 Replacing the filter cartridges Disconnect the control unit from the mains supply for the dedusting. Disconnect the compressed air container from the external compressed air supply. Empty the compressed air container (pos. 20) in opening the discharge cock (pos. 22). When opening the ball cock, small amounts of condensate may escape.) Release the acorn nuts of the maintenance door for the cartridges (pos. 8) and remove the door. Release the locking screw (pos. 19) of the cartridge bracket (pos. 18). Withdraw the filter cartridges (pos. 17). Hang a new filter cartridge into the cartridge bracket (pos.18) Only use TEKA spare filters! Fix the locking screw (pos. 18) of the cartridge bracket (pos. 17). Fix the maintenance door for the cartridges (pos. 8) to the filter housing (lever on the right side!) with the help of the acorn nuts. Connect the compressed air container to the external compressed air supply. Connect the control unit for the dedusting to the mains supply. (Observe the indications on the nameplate!) Only replace and dispose of filters in sufficiently ventilated spaces and in wearing an appropriate respiration protection! Empty the compressed air container before performing any kind of maintenance or repair task. We recommend: Respirator half mask according to DIN EN 141/143 protection level P3. Only a sufficiently instructed employee is authorized to perform the steps mentioned above! Dispose of the filter cartridges according to the legal regulations. 6.6 Relubricating the fan The motor bearing of an 11 kw fan has to be relubricated every 5000 operating hours. By default, the motor is delivered with lithium saponified greases as lubricant. To relubricate the bearing, you can use lithium soap-based greases with a mineral base oil. When the bearings have been relubricated several times, clean the grease chamber and replace the bearing if necessary. The relubrication has to be performed when the motor in running! BA_Filtercube-MV_120613_GB.doc 11 13.06.2012

7 Disposal To make sure a proper operation of your TEKA filter unit as well as an appropriate disposal of the separated dust, we offer you the following services: We help you to find a waste disposal company in your region. On demand and free of charge, we provide you a list with all waste disposal companies in Germany. Conclusion of a maintenance and service contract A costumer help line For these options, please contact our service department that is at your disposal. Phone: 0 28 63 / 92 82-0 Fax: 0 28 63 / 92 82 72 8 Control of the device For information concerning program settings etc., please consult the separately attached instruction manual. 9 List of spare parts Designation: Article no. Suction turbine 3kW 200421160300003 Suction turbine 5,5kW 200421160550004 Suction turbine 11kW 200421161100013 Filter cartridge 7,8m² 10025078 Filter cartridge 10m² 10025 Filter cartridge, type easy clean+, 12,5 m² 100050125 BA_Filtercube-MV_120613_GB.doc 12 13.06.2012

10 Technical data Observe the indications on the nameplate! Filter unit TEKA FILTERCUBE-MV Supply voltage V 400 Frequency Hz 50 Type of current Ph 3 Motor performance kw 3,0 5,5 11,0 Volumetric air flow max. m³/h 500 1000 2000 Negative pressure max. Pa 10000 10000 10000 IP rating IP 50 ISO class F Control voltage V 24 Width x depth x height mm 800 x 800 x 2664 Weight without filter cartridges kg 580 Filters Filter cartridges Filter surface of the filter cartridges m² 31,2-50 Extraction performance % >99 Type of dedusting Compressed air Pulse-Jet External Pressure min. bar 4 Pressure max. bar 6 Compressed air supply dry / oil free BA_Filtercube-MV_120613_GB.doc 13 13.06.2012

11 Declaration of conformity for TEKA-Filtercube-MV TEKA TEKA Absaug - und Entsorgungstechnologie GmbH Industriestraße 13 D - 46342 Velen Tel.:+49 2863 92820 Fax:+49 2863928272 email: sales@teka.eu Internet: http://www.teka.eu We hereby declare under our sole responsibility that the product mentioned above, from the machine number 7000010011001 on, conforms to the following directives: Machinery directive: Electromagnetic compatibility: Pressure equipment directive: Low voltage directive: 2006/42/EC 2004/108/EC 97/23/EC 2006/95/EC Applied harmonized standards: - DIN EN 349 - DIN EN 983 - DIN EN 12100 part 1 and part 2 - DIN EN 60204 part 1 - DIN EN ISO 13857 - DIN EN ISO 14121 Plus further national standards and specifications: - DIN 45635 part 1 This declaration will become void if the suction and filter unit is exposed to modifications that are not approved by the manufacturer in written form. Velen, December 29, 2009 BA_Filtercube-MV_120613_GB.doc 14 13.06.2012