INSTRUCTION MANUAL ENGLISH CAPTURE AT SOURCE FILTERMAX NR /

Transcription

1 INSTRUCTION MANUAL ENGLISH CAPTURE AT SOURCE NR. 898 / -9-

2 Installation Operating Starting Settings Service Repair Accessories Protocols List of contents CE, Declaration of conformity Delivery check IMPORTANT! Safety imformation Pre-installation Technical data Dimensions Mounting instructions Mounting the filter cartridges Compressed air connection Electrical installation Accessories, electrical installation Earth control measuring Applications Wiring diagram Connection of several FilterMax to one system Connection of or pilot boxes Fans Duct dimensioning / System installation Operating description Starting the system Monitoring system, settings Monitoring system, general descriptions Monitoring system, fault indications Service instructions Trouble-shooting schedule Spare parts Accessories Installation protocol Service protocol Service protocol page FilterMax FilterMax 6 FilterMax 9

3 This product is designed to meet the requirements of the relevant EC directives. To maintain this status all installation, repair and maintenance work must be carried out by qualified personnel using only original spare parts. Contact your nearest authorised dealer or AB Ph. Nederman & Co. for advice on technical service or if you require spare parts. Declaration of conformity We, AB Ph. Nederman & Co., declare under our sole responsibility that the Nederman product: - FilterMax serial 667 with accessories to which this declaration relates, are in conformity with the following standards or other normative documents: EN 86- following the provisions of Directive 7//EEC, 89/6/EEC and 87//EEC. AB Ph. Nederman & Co. Sydhamnsgatan S-5 8 Helsingborg Sweden -9- Alf Jonasson, Product Manager DELIVERY CHECK The following Nederman FilterMax modules should be mounted together to assemble the complete FilterMax. When delivered A - G are already assembled (units shipped by sea may contain more components). A. Filter unit (, or pcs.) B. Stand C. Collector ( x litres or x litres with stand extentions) G D. Control box E. Pre-separator A, H F. Deflector G. Top unit H. Additional unit J. Inlet K. Outlet E L. Filter cartridges (6 pcs./filter unit) F J K L The units should be checked for any damage that may have occured during transport. If there is damage or parts missing, the carrier and your local Nederman representative should be notified immediately. FilterMax can be supplemented by a number of accessories ( see page ). B C D C

4 IMPORTANT! SAFETY INFORMATION Nederman FilterMax is designed for collecting and filtering fume and non-explosive dry dust. To guarantee the correct function and a minimal service FilterMax must only be used for these purposes and according to the instructions in this manual. The manual contains important warning directions which have to be read and followed. Any functional disorders, especially those affecting the safety of the machine, should be rectified immediately. For safe and reliable results assembling work, electrical installation, use, service and trouble-shooting should be performed by qualified personnel. Special training may also be necessary. Please contact your nearest authorised dealer or AB Ph. Nederman & Co. for technical advice. PRE-INSTALLATION min. Nederman FilterMax can be installed indoors or outdoors. FilterMax should be located with consideration for easy handling of the collected dust and for convenience of service and maintenance. Nederman FilterMax is usually installed on a reinforced concrete foundation. However, installation on another structure is also possible. When calculating for foundation or supporting structure the following factors should be taken into consideration (see technical data): Total weight of FilterMax Max. weight of collected contamination Possible wind load Possible snow load IMPORTANT! Location must be clear of all obstructions such as utility lines etc. Pay particular attention to the anchor bolt location. Anchor bolts (M6) must extend at least 6 mm above foundation. If you intend to secure the unit by using expansion bolts or equivalent fittings, the concrete floor must be prepared accordingly. max min TECHNICAL DATA Filtration Operating airflow Filterarea/filter cartridge Filter material Operating temperature Process air (dry) temperature Material description Compressed air requirements Compressed air consumption Compressed air connection Voltage supply Protection class Relay voltage Working pressure Pulse noise Weight Basic filter: 99% at, µm (after some time in operation), BIA class C PTFE filter: 99,9% at. µm, BIA class C module: - 6 m /h (depending on load and application) modules: 8-7 m /h (depending on load and application) modules: 7-8 m /h (depending on load and application) module: 6 m, modules: m, modules: 8 m layer cellulose/polypropylene - C to +6 C C to +6 C, not condensing mm painted steel, epoxy based zinc prime and top coat,6 MPa (6 bar / 87 psi), water and oil free N-litres / cleaning pulse, at,6 MPa (6 bar / 87 psi) /" R 5 V, V, V, 5/6 Hz IP 5 V AC, max 6 VA to -5 kpa, not overpressure Lp Aeq, s, 5 db module: 65 kg, modules: 89 kg, modules: 5 kg

5 DIMENSIONS G MODULES F A B C OUTLET MODULES INLET MODULE E 5 D 7 9 H x litres containers NB! The height dimensions for the filter are only valid when using the litres containers. open angle A B C D E F G H In/Outlet inner diameters (mm)

6 MOUNTING INSTRUCTION WARNING! Risk of personal injuries and/or product damages! Use approved lifting equipment for unloading, assembly and installation of the units. Use schackles, not hooks on the lifting sling. Connect the lifting sling to cabinet lifting lugs. Distribute loads equally. NB! For most deliveries the deflector, acceleration nozzle and top unit are already mounted. In that case step no. and in this mounting instruction can be excluded. x NB! Maximum units should be lifted at the same time.. Dust container x litre is mounted when delivered. If dust container x litre should be mounted the stand extensions also must be mounted.. FilterMax is usually anchored to a concrete foundation with expansion bolts or similar. Fit the fixing bolts and use adjusting pieces, if necessary, to get the filter unit in level. Check with a spirit level. For more stabilty, the filter unit can be braced against the wall.. Fit the deflector in the filter module. If or modules are used the deflector should be fitted in the upper module.. Mount the top unit on to the upper module. Fit the acceleration nozzle in the top unit. 6

7 IMPORTANT! Ensure that the inlet, outlet and all filter units always are mounted together with bolts in all intended holes. Always use toothed washers to ensure electric connection. NB! The inlet and outlet are reversable and concequently they can be positioned for duct connection on the right or left side of the filter.. For FilterMax 6 and 9 two and three filter units are used respectively. Mount the units together to build the complete filter unit. 6. Fit the inlet and outlet. (NB! The inlet is equipped with an inspection cover on top.) MOUNTING THE FILTER CARTRIDGES. Unscrew the two fixing screws on the access door. Use the enclosed T-key or a mm standard hexagon key. Open the door.. Loosen the nuts on the filter holders but don t screw them off completely. Remove the filter holders.. Handle the filter cartridges carefully to avoid mechanical damage to the filter surface.. Insert the filter cartridges. NB! The mark on the back plastic end cap should be put on the angled sheet-metal plate just inside the filter hole. WARNING! Risk of personal injury! For FilterMax equipped with or modules ( or 8 filter cartridges), an approved lifting platform (see figure) has to be used when mounting or replacing the filter cartridges. 5. Hang the filter holders on the screws and fasten the nuts. 6. Shut the access door and fasten the two fixing screws. 7

8 COMPRESSED AIR CONNECTION Connect the compressed air supply line to the compressed air connection of the filter. Use pipe sealant on all compressed air connections. Compressed air components (accessories, see page. ) A shut off valve for service work and a filter regulator should be installed in the compressed air pipe line (NB the flow direction during the installation). Important! the filter regulator must be positioned in a frost free environment. Recommended connection size: minimum /". Compressed air tank, module no. Water drain valve Compressed air tank, module no. Water drain valve FilterMax Control box Pressure switch (accessory) Sevice valve (accessory) Filter regulator, should be set on, -,6 MPa ( - 6 bar / psi) (accessory) Compressed air connection Compressed air tank, module no. Water drain valve IMPORTANT! The compressed air supply pressure has to be =, -,6 MPa ( - 6 bar / psi). The compressed air shall have a dew point below the minimum temperature at which the system is ment to be used. The compressed air supply must be both oil and water free. Improper air pressure or contamination in the compressed air can result in cleaning valve failure, poor cleaning and filter performance. Purge compressed air lines to remove debris before connecting to the compressed air manifold. Do not use thread-sealing tape after the filter regulator. Quick couplings throttle the air too much and are not recommended. Turn off and bleed off compressed air supply before doing any service work. Do not pressurise the system if the air temperature is below the minimum operating temperature, that is - C. At lower air temperature the process could be started and be in operation for a while (approx. 5 min.) after which the system can be pressurised. 8

9 ELECTRICAL INSTALLATION WARNING! Risk of personal injury! Disconnect the electrical power before servicing any electrical component. All exposed conductive parts of the electrical equipment and the machine shall be connected to the protective earthing (see wiring diagram). IMPORTANT! All electrical work must be done by a qualified electrician according to local regulations. Connect FilterMax to the mains and connect fan and other components and accessories according to the following wiring diagrams. A lockable safety switch should be fitted on the mains connection cable. Electrical connection together with Nederman Fan Starter or Fan Inverter is described on wiring diagrams supplied with these products. ACCESSORIES, ELECTRICAL CONNECTION Connecting fan and other accessories to the FilterMax as well as connecting the FilterMax to the mains must be done by a qualified electrician. Connection block JP : Digital inputs External START/STOP Pressure switch, compressed air High dust level Pressure switch, high dp / low airflow / simple dp control Spare, not used Fan motor protector Fire alarm The accessories must be equipped with a potential free contact Connection block JP 6: Outputs Fan starter ( V AC) Down time damper ( V AC) Dust feeder ( V AC) Automatic depressurising of compressed air tanks at fire Alarm signal (A or S), V AC A-Alarm, potential free contact, V AC Fan starter potential free contact, V AC JP JP Alarm device Dielectric detector PNP > P Start contactor Damper motor Fan start equipment P > bar Pressure switch Automatic depressuring of compressed air tanks at fire Compressed air tank on FilterMax Frostless Normally closed valve with big bore. Normally opened valve. Compressed air connection. Filter regulator Both valves shall be connected to JP6:, /, so they will be activated (drawn) at normal operation. At a possible fire alarm (or a power failure) the valves are switching and the compressed air tanks will be depressurised. 9

10 WARNING! Risk of personal injury! Electric power connected! ACTIVATING INPUTS AND OUTPUTS The inputs or outputs should be activated when accessories have been connected. Push the button (X) on the back of the control box cover to activate actual input/output. The LED s indicate, where appropriate, with red blinking lights. The inputs are activated in the following order: X Selecting OFF, NC or NO Push the control box button and OFF, NC or NO comes up on the display. OFF: The selected input is not activated. NC = Normally closed: The selected input is activated. NO = Normally opened: The selected input is activated. Select NC or NO depending on type of contact on the connected accessory. Make a note of the setting which has been selected. or NC or NO A Blinking OFF Motor protector, fan Push the button X. Activated input: JP: 6 Set OFF, NC or NO with the /-button. OFF NC NO or NC or NO B OFF Blinking High dust level Push the button X. Activated input: JP: Set OFF, NC or NO with the /-button. OFF NC NO or NC or NO C OFF Blinking Pressure switch, compressed air Push the button X. Activated input: JP: Set OFF, NC or NO with the /-button. OFF NC NO or NC or NO D OFF Blinking Pressure switch high dp / low airflow Push the button X. Activated input: JP: Set OFF, NC or NO with the /-button. OFF NC NO

11 E or NC or NO EA OFF Fire alarm Push the button X. Activated input: JP: 7 Set OFF, NC or NO with the /-button OFF NC NO F df or OFF or Int ON Dust feeder Push the button X. Activated output: JP6: Direct controlled by contactor or other V relay. ON: The dust feeder is in operation OFF: The dust feeder is not in operation Int: Intermittent operation of the dust feeder Set ON, OFF or Int with the /-button. ON OFF Int G da - 6 s Down time damper delay Push the button X. Activated output: JP6: V AC supply for opening a damper motor with spring return or magnetic valve for compressed air. Is used to reduce the starting current at fan start. Delay time for opening the down time damper: - 6 s after fan start. Set the required delay time with the /-button. H LINE LINE-connection Push the button X. Connection to JP, see page Set LINE, LINE or LINE with the /-button. LINE LINE LINE J LO or OFF ON Local START/STOP Push the button X. Activated input: JP: Inactivates the start/stop button on the control box. Only remote start is possible in OFF-position. Set ON or OFF with the /-button. ON OFF K or NC or NO OFF Slow green blinking during operation. Fast green blinking during cleaning. Simple dp-control of the cleaning. Switch off the main switch.. Connect a pressure switch ( - kpa) to JP, inlet plus 9 or.. Push the control box switch (/-button) and the button X on the back side of the control box cover.. Switch on the main switch. NB! The /-button and the button X must be pushed at the same time while the main switch is switched on. 5. Set the pressure at which the cleaning shall start (normally - 8 Pa). Set OFF, NC or NO with the /-button. OFF NC NO

12 EARTH CONTROL MEASUREMENT Earth control measuring must only be done by a person with necessary knowledge. IMPORTANT! All metal parts of the filter unit must be earthed reciprocally and connected to earth. To secure this, the following procedure must be followed. When the FilterMax has been installed and during maintenance work the earthing shall be measured. The measuring is done between GND (in the Control Box, see picute below) and the following components on FilterMax. Disconnect protection earth from GND before measuring.. Inlet. Cleaning access point (on the inlet). Dust container. Adapter for dust container 5. Filter cartridge 6. Filter module 7. Door Reconnect protection earth to GND. Circuit card FilterMax Control Box JP 6 Disconnect at earth control measuring 7 GND APPLICATIONS Nederman FilterMax separates for instance welding fume, metal oxides, talcum, lime stone, paint powder and grinding dust. FilterMax must not be used for separating explosive contaminations. Explosive dusts are dry organic dusts and some metallic dusts. The metallic dusts are, for example, aluminium, magnesium, titanium, chromium and fine virgin dusts of other metals. Welding fumes from these metals are not explosive, but grinding dust is a problem. Please contact your Nederman representative in case of doubts. Various combinations of semi combustible fumes/dusts (oil, grease) and sparks can cause fires when grinding or welding. The most important action is to prevent sparks from entering the extraction devices. Secondly it is very important to perform regular cleaning of the extraction arms/devices and the duct system. FilterMax does not separate gases. WARNING! Risk of personal injury! In some countries the purified air must not be recycled in the workshop if FilterMax is used to separate welding fume or some contaminations that may be a health hazard. Risk of fire or explosion! - Do not use FilterMax to separate explosive fume or dust. - Grinding, welding or other hot works on the filter exterior or inlet must not be done without cleaning and stopping the operation. - Connect a fire alarm to the filter controling processor, which means the filter will stop at a possible fire. - Care should be taken when working with painted or heavily oiled material. Consult your Nederman representative for advice. - FilterMax must not be exposed for burning/glowing material.

13 CONNECTION TO THE MAINS CONNECTION OF: FAN STARTER SAFETY SWITCH (Nederman accessory) AFTER CLEANING DAMPER PRESSURE SWITCH (Nederman accessory) PILOT BOX (included in the delivery) FAN (Nederman accessory) WIRING DIAGRAM Designations, Circuit card FilterMax control box: JP: Inputs S: Pause time JP: Power supply S: Down time JP: Pilot box S: Remote auto restart, JP5: A-alarm off On A-alarm JP6: Outputs NB! connection between and on the last pilot box. NB! After cleaning damper with spring return should be connected only to JP6 no. and no. 8. Motor After cleaning damper Open Supply Com Fan starter Control voltage V A max JP5 JP A S S S Circuit card FilterMax Control box JP Door Pilot control { - + JP JP Pilot box GND 5 6 M > P Mains-connection Endast V, PE, 5/6 Hz Mains-connection // V, PE, 5/6 Hz For fan start, two alternatives are possible. Alternative : Connection to block JP6: ( V AC), for direct control by contactor or other V relay. Alternative : Connection to block JP6: 8-9, potential free relay output, is used when the start equipment has its own V control voltage, for example Nederman Fan Starter (which is recommended). The complete connection is described in the Fan Starter Instruction Manual. Pressure switch BASIC FUNCTIONS. Down time damper Alt.. Electric motor open and close Alt.. Electric motor open, Spring return Alt.. Magnetic valve for compressed air operated damper with spring return.. Transformer. Pressure switch, compressed air FilterMax Wire to JP6 : and or (common) and the lower V AC output from the transformer (). Wire to JP6 : and or (common). FilterMax - Wire to JP : and 9 or (common). Select NO in the software setting if an OPEN contact indicates OK. Select NC in the software setting if a CLOSED contact indicates OK.

14 CONNECTION OF SEVERAL TO ONE SYSTEM LINE LINE s pause time between cleanings s s pause time between cleanings LINE NB! connection between and on the last pilot box. LINE LINE LINE pause time between cleanings NB! Remove the connection between and on the output contact before the cable from the pilot box above is connected. S S S { - + Door Pilot control JP Circuit card FilterMax Control JP Box GND JP IN OUT IN OUT IN OUT Set LINE, LINE or LINE with the /-button on the Control Box. GND to filter house GND to filter house GND to filter house NB! connection between and

15 CONNECTION OF OR PILOT BOXES JP JP NB! connection between and on the last pilot box. NB! Remove the connection between and on the output contact before the cable from the pilot box above is connected. Total pressure Pa FANS NCF 6/5 NCF /5 NCF /5 NCF 5/5 NCF 8/5 NCF /5 NCF 8/5 NCF /5 NCF /5 6 8 m /h Air flow Each FilterMax can be connected to an existing central fan or to a fan dimensioned specially for the system. An adequate fan can be selected from the Nederman NCF-range. Please contact your Nederman representative for dimensioning the right fan capacity. Calculated air pressure drop over the filter is approximately Pa. A lockable safety switch is recommended for the whole electric system including the fan. 5

16 DUCT DIMENSIONING AND SYSTEM INSTALLATION Cleaning access point Cleaning access point Flow meter After cleaning damper Nederman Original Fume Extractors with automatic dampers - 5 Nederman NCF fan Ø 5 / 5 mm NB! To adjust the air flow, a regulating damper in the clean air duct can be used. As an alternative the air flow can be controlled with Nederman fan inverter (accessory, see page ). Recommendations To avoid pressure losses and dust deposits in the system it is important to use the correct duct diameter. The transport velocity shall be at least - m/s for fume and 5 - m/s for dust. Take velocity in to account when choosing the duct diameters. The velocity should never decrease en route to FilterMax. The following duct diameters can be used for the connection to FilterMax. module moduls moduls Inlet Ø 5 / mm Ø / 5 mm Outlet Ø 5 / mm Ø / 5 mm Ø 5 mm Use long radius bends and no t-pieces. If the dust is abrasive it may be necessary to use thick walled (or rubber coted) material in bends and other exposed areas. WARNING! Fire risk! - Grinding, welding or other hot works on the filter exterior or inlet must not be done without cleaning and stopping the operation. - Connect a fire alarm to the filter controling processor, which means the filter will stop at a possible fire. - Care should be taken when working with painted or heavily oiled material. Consult your Nederman representative for advice. - FilterMax must not be exposed for burning/ glowing material. Install plenty of cleaning access points in the ducting system before FilterMax. To avoid pressure losses the ducting system should be as short as possible and designed with two or more branches. Use larger diameters on the clean side to reduce pressure losses. Use fire dampers when the duct system is passing from one fire zone to another. NB! Fire dampers do not stop explosions! FilterMax monitoring system has an input (JP- 7) for fire alarm which, when activated, immediately stops the filter and a possible after cleaning damper (fire damper). Install a flow meter between FilterMax and the fan. If there is a significant fire risk, it is better to install several small systems then one large system. Install a sparktrap to prevent sparks or burning/glowing material from entering the FilterMax. NB! Larger objects can block the pre-separator in the filter unit. To prevent this, a protective grating should be fitted in the inlet duct. 6

17 OPERATING DESCRIPTION It is recommended to use a downtime damper (see accessories, page ) which should be mounted close to the inlet. The damper closes the duct when the filter is shut off, which will prevent dust from being transported back into the workshop by the air pulses from the down time cleaning. The contaminated air is led through the inlet which is shaped to distribute the air evenly into the accelerator nozzle of the preseparator. Inside the inlet there are four air distribution blades that further enhance the air distribution. This design also minimises the pressure loss in the inlet. In the accelerator nozzle the particle loaded air is accelerated to several times the inlet velocity. After the pre-separator the air stream is led up and distributed downward, by the sloped roof of the filter towards the filter cartridges. The filter media in the cartridges collects the remaining particles. After a short distance the air jet is forced to turn 8 degrees over a slot formed by the back wall of the filter and the deflector plate. The cleaned air exits through the outlet in the top of the front part of the filter. Collection chamber leading down to the pre-separator dust container. Larger particles will slip out of the air stream due to their inertia. The pre-separator has an efficiency of around 8 % for particles larger then 5 µm. Pre-separator dust container Cartridge separator dust container Valve with cleaning pipe The filter cartridges are cleaned one by one with powerful air pulses. The air pulses are distributed into the slot shaped outlet of the filter cartridges. This generates a quiet and efficient cleaning pulse. The filter controller controls the cleaning process. The filter cartridge seen from above 7

18 STARTING THE SYSTEM. Turn on the compressed air supply to the cartridge filter. Adjust to, -,6 MPa ( - 6 bar, psi) of pressure. Pressure of,6 MPa is the most typical setting for satisfactory cleaning performance.. Close the regulating damper halfway, see figure, page 6. (As an alternative the airflow can be controlled by a fan inverter (accessory, see page ).. Start the fan and check fan impeller rotation. Refer to the rotation sticker on the fan motor. Proper fan impeller rotation is extremely important. Contact a qualified electrician if the impeller rotation must be reversed. Impeller rotation direction WARNING! Risk of personal injury! Stand clear of blower fan exhaust area as debris can be exhausted and cause injury.. Adjust the fan for the proper system airflow that is desired by adjusting the regulating damper. The air flow can be measured with a fixed airflow meter (or a pitot tube) and a micro-manometer. IMPORTANT! Too much airflow can cause electrical system failure and dramatically reduce the life of the filter element. 5. All the solenoid valves should open and close continuously with a set interval time between each cleaning pulse (factory set of seconds). Check operation of the solenoid valves in the following way: Set the pause time on s (position on S in the connection box, see picture). NB! This is only a control setting and should not be used for normal operation. Start the system and count the number of air pulses. It should be 6 pulses per module. NB! Return the pause time to the original value after checking S Connection box V V V V MONITORING SYSTEM, SETTINGS CLEANING DURING OPERATION FilterMax is in its standard design equipped with a fully automatic compressed air cleaning of the filter cartridges. A piping system directs, by a system of solenoid valves, air pulses of ms into the filter cartridges. The pause time between the air pulses is factory set at s, but can be set between 5 s and 9 s (S). Shorter pause time can be used if more than module is used or if FilterMax is used for heavy load. RECOMMENDATIONS FOR PAUSE TIME SETTINGS The pause time setting depends on the size of the filter (i.e. the number of cartridges) and the load at which the filter is working. Light load - A dust that is easy to clean off the filter cartridges, such as dry stone dust or grinding dust. Normal load - Applications such as welding fume or Light dusts in heavy concentrations. Heavy load - Typically metal cutting with Laser or Plasma and heavy welding. Model / Dust load FilterMax FilterMax 6 FilterMax 9 Light 9 s * 6 s s Normal 6 s s 5 s The factory setting is s for all FilterMax. * or no on line cleaning Heavy s 5 s s With light load the cleaning pressure could be reduced to.5 MPa (5 bar). Check that the filter pressure drop does not rise too quick. If so, the pause time could be reduced with one step and the cleaning pressure could be increased, but maximum to.6 MPa (6 bar). 8

19 S PAUSE TIME S DOWN TIME S REMOTE AUTO RESTART ON A-ALARM CLEANING AFTER OPERATION It is possible to choose cleaning after operation, that is when the fan has stopped. This is more efficient than cleaning during operation and is therefore recommended. The pause time at cleaning after operation is always 5 s. If cleaning after operation has been chosen, one has to set the desired number of cleaning cycles (S ), where one cycle means the cleaning of all filter cartridges, that is 6, or 8 cartridges, depending on the number of modules in operation. - cycles are recommended depending on the dust load (light - normal) When cleaning after operation it is recommended to use an after cleaning damper (see accessories page ). S S S V V V V s (for test) 5 s s 5 s s 5 s 6 5 s 7 6 s 8 9 s 9 No cleaning during operation, A-ALARM FUNCTION The A-alarm-function is always ON when the system operates, which means if there are negative influences on the function during operation, the A-alarm will release, that is LED no. 7 will show a red fixed light. It is possible to choose the following functions for A-alarm by setting S. For fume/dust generating processes that can t be stopped immediately when a fault accurs it is recommended that the A-alarm switch is set to ON and that a clearly visible alarm device is installed. ON The system does not stop when the A-alarm is activated. With exception for explosion/fire-alarm and motor protection, fan. The system always stops for these functions. OFF The system stops automatically when the A-alarm is activated. REMOTE START It is possible to choose the following functions for Remote start by setting S. For most filters that are remotly started from a machine or a process eg. it is convenient to set the Remote start switch S to ON. OFF When using remote start there is no automatic restart when a fault has been rectified. The remote started mashine must be stopped and the FilterMax must be reset by one push on the start button before a new remote start can be done. ON When using remote start there is automatic restart when a fault has been rectified or after a power failure. The remote start control should be connected to JP and 9 or (see page 9). If remote start is used, the system can not be stopped with the /-button on the Control Box. cycle cycles cycles cycles 5 5 cycles 6 6 cycles 7 7 cycles 8 8 cycles 9 9 cycles ON 9

20 MONITORING SYSTEM, GENERAL DESCRIPTIONS The display on the control box gives information about the number of operating hours, cleaning process, alarm functions and possible faults. Blinks when the cleaning function operates. The LED:s can indicate the following:,,,, 5 green fixed light: All functions normal and correct,,,, 5 green fixed light alternating with blinking red: The system operates. Incorrect function has been rectified (alarm memory),,,, 5 red fixed light: Incorrect function which requires investigations. 6 yellow fixed light: Incorrect function which requires attention. 7 red blinking light: Incorrect function which requires immediate investigations.,,, 5 is only active after the inputs for the accessories has been activated (see page ). Fixed light when the system operates. The total number of operating hours are displayed. r E r E is displayed when trying to stop the system from the control box when the system is remote started. Both "point" and blinks when cleaning after operation is in progress. The system has stopped and the cleaning after operation is active. If the / button is pressed once more the cleaning after operation is stopped immediately.

21 MONITORING SYSTEM, FAULT INDICATIONS Blinking The fan motor overload protector is released. Check the cause. Rectify the fault and reset the motor protector. FilterMax always stops when the motor protector is released. Possible faults (depending on how the input has been used):. The pressure drop over the filter is high.. The air flow in the system is too low. Check if the filter cartridges are saturated, change if necessary. Check if any damper is not open enough. Check the inlet for dirt. Clean if necessary. Low pressure in the compressed air supply. FilterMax will not start. Blinking Blinking FilterMax has stopped due to low compressed air pressure (less than, MPa ( bar)). FilterMax will not start until correct pressure is resumed. A-alarm! Means acute problems which could disturb the function of the system. Action should be taken as soon as possible. Call for a service technician. Example: More than valve is defective or does not work. It is displayed which valves that are defective (Err +,,,... 8) are displayed, alternating with the number of operating hours). Electronic faults on the circuit card. EA Blinkande Fire alarm. Call for service technician. Check the reason and do not start the system until the fault has been rectified.

22 MONITORING SYSTEM, FAULT INDICATIONS (Continuation) Service requirements! Should be rectified as soon as possible. Example: One valve is defective or does not work. It is displayed what valve that is defect (Err + the defective valve no. ( - 8) is displayed, alternating with the number of operating hours. Blinking The door has been opened during system operation. Shut the door. The door is open and FilterMax will not start. The dust container is full. Empty the container. r E A Blinking r E A is diplayed (alternating with the number of operating hours) in combination with a motor error and a desplayed A-alarm at remote controlling. p F a i l There has been a power failure. Reset by pressing the / button. If the filter is remotely started it will start directly when the / button is pressed.

23 SERVICE INSTRUCTIONS In order to ensure that the system continues to operate correctly, the following should be checked at periodic intervals depending on what kind of contaminations that are separated and the amount of use. Defective and worn parts should be replaced immediately. EMPTYING THE DUST CONTAINER IMPORTANT! Empty the dust containers when they are approximately 7 % full. Do not let them overfill. It can cause poor filter performance and cause an extensive clean up work due to overflow of dust when removing the containers. Normal working light is required for emtying the containers. Inspect how much the containers have been filled in the beginning of the filtering process, to make it possible to estimate a normal emptying interval.. Switch off the FilterMax.. Put a pallet, which can be operated by a lift truck, under the dust containers.. Loosen the dust containers by realising the excentric locks. Let the containers down to the pallet.. Empty the dust containers. Disposal of dust should be in accordance with local regulations. 5. Check that the gasket between the filter and dust container not is damaged. 6. Put the dust containers back under the filter and fit them with the excentric locks, Check that the gasket between the filter and container is correctly fitted and seals after locking. WARNING! Risk of personal injury! Use protective goggles, breathing mask and gloves when doing servicing and repairing work inside the system, specially when replacing the filter cartridges and emptying the dust containers. Avoid contact or exposure to dust as much as possible during servicing or maintenance. Shut-off and bleed compressed air supply before opening the inspection door and servicing any compressed air components. Disconnect electrical power before servicing. CHECK WHEN EMPTYING THE DUST CONTAINER Check if there is water (or oil) in the filter regulator. In that case, the compressed air is not dry enough and there is a risk of damage to the filter cartridges. Check that the pressure is set to. -.6 MPa ( - 6 bar, psi). If there is water in the filter regulator container, check that there is no water in the pressure tank (tanks), by opening the drain nipple on the right bottom side of the tank. Filter regulator container

24 SERVICE AFTER OPERATION HOURS, BUT AT LEAST ONCE EVERY 6TH MONTH Check that all valves in the cleaning system operate properly. Count the number of air pulses, 6 per module, that is 6, or 8 per cycle. Remove dust collections from the lower part of the clean air room. SERVICE AFTER OPERATION HOURS, BUT AT LEAST ONCE A YEAR OR WHEN REPLACING FILTER CARTRIDGES Unscrew the inspection covers on the top unit and on top of the inlet. Check the seals. Clean when necessary. Check that there is no water in the pressure tank (tanks), by opening the drain nipple on the right bottom side of the tank. Check the filter cartridges. They should be replaced if the outer surfaces are damaged or if the air flow through FilterMax is insufficient due to saturation of the filter cartridges despite repeated cleaning. Take measures against possible corrosion by grinding, primer and touch up paint. Earth control measurement (see page ) GND - Inlet GND - Inlet cleaning access cover GND - Dust container GND - Dust container adapter GND - Filter cartridges GND - Filter units GND - Doors Inspection covers REPLACING THE FILTER CARTRIDGES AT DAMAGE OR INSUFFICIENT FILTER FUNCTION, BUT AT LEAST AFTER 6 OPERATION HOURS WARNING! Risk of personal injury! For FilterMax equipped with or modules ( or 8 filter cartridges), an approved lifting work platform (see figure) has to be used when exchanging the filter cartridges. Instructions for replacing the filter cartridges, see next page. After 6 operating hours, also check that the cables not are damaged or connected incorrectly.

25 REPLACING THE FILTER CARTRIDGES. Switch off the FilterMax.. Shut off and bleed the compressed air.. Unscrew the two fixing screws on the access door. Use the enclosed T-key or a mm standard hexagon key. Open the door.. Loosen the nuts on the filter holders but don t screw them off completely. 7. Hang the mounting frame with the plastic bag over the plastic end of the filter cartridge. Draw the whole cartridge in to the plastic bag. 5. Remove the filter holders. 8. Remove the mounting frame and fold the plastic bag in a way that the filter cartridge will be completely enclosed and sealed. 9. Proceed in the same way with the remaining filter cartridges.. Inspect the filter housing and look for damage, dust layers etc. Clean inside the filter housing. A vacuum cleaner is recommended.. Handle the new filter cartridges carefully to avoid damage.. Insert the new filter cartridges. NB! The mark on the back plastic end of the filter cartridge should be put on the angled sheet-metal plate just inside the filter housing.. Hang the filter holders on the screws and fasten the nuts.. Check the access door seal. Shut the door and fasten the two fixing screws. 5. Turn on the compressed air supply. 6. Draw a plastic bag through the opening in the enclosed mounting frame, as the picture shows. 5

26 TROUBLE-SHOOTING SCHEDULE FilterMax will not start. Are there any LED s on the controlbox panel that are on. NO YES A Possible faults Control questions Actions Is the A-alarm LED no. 7, on? IMPORTANT! Turn off the compressed air supply with the service valve before doing any work on the cleaning system. Do not pressurise the system if the air temperature is below the minimum operating temperature (= - C). At lower air temperatures the process can be started and operated for a while (approx. 5 min.) whereafter the system can be pressurised. Check the fuses on the card and the power supply to the card. If the power supply and the fuses are fully functional, contact your nearest Nederman representative for more assistence. NO YES Are you trying to remote start the filter? Correct the error indicated by the function LED s, see page -. NO YES Check that the wiring is correct. Closing + 9 or shall start the filter. Contact your nearest Nederman representative for advice. FilterMax starts, but stops after a while and the display shows ERR + a digit. B Is the display showing ERR? YES NO The cable connecting the controller to the first pilot box is not properly connected. FilterMax starts, but the fan will not start. C Is the display showing ERR + another digit than? NO YES Contact your nearest Nederman representative for advice. Check that the electrical wiring for the fan start is done correctly between and output common ( or ) on the outputs (block JP6). See wiring diagram, page. There is an electrical fault in one or more of the pilot valves. The number/s shown after ERR are the number of the faulty valve/s. Depressurise the system. Check that the leads to the valve coil are properly connected. Remove the leads and measure the resistance of the coil, it shall be approximately 6 Ω. If the resistance is more than 9 Ω or less than Ω or if the coil circuit is cut, replace the pilot valve. 6

27 The FilterMax pressure resistance is high. D Is the cleaning system fully functioning? NO YES Check the pressure of the compressed air. It should be,6 MPa (6 bar, 87 psi). Are there some valves that are functioning? NO YES Go to B Go to F If the Advanced Control box is installed go to the Advanced Control box manual section regarding the adjustment of cleaning the system. Otherwise, check the pause time set on the timer (see page 9). The default value is s. A heavy application or a - module unit ( - 8 filter cartridges) will require shorter times. A very light application can use longer times. If the cleaning has been adjusted previously you may have to replace the filter cartridges. The airflow is insufficient. E Is the pressure resistance high ( >-5 Pa)? YES NO Has the airflow been satisfactory? Go to D Contact your nearest Nederman representative for advice. NO YES YES Is the fan operating correctly? Does the impeller rotate in the right direction? NO Check the rotating direction of the fan impeller. Compare with the arrow on the label on the fan motor. It is very important that the rotation direction is right. If the impeller rotates in the wrong direction, the fan gives only % of its possible air volume. Contact a qualified electrician if the impeller rotation must be reversed. Check if the system contains any dampers and the position of these. Open dampers to adjust the flow, but don t exceed the dimensioned airflow for the filter unit. Check that the filter unit s inspection panels are closed. Check the fan for blocked outlet or other damage. Open the filter unit s inlet inspection door on the top of the inlet and check for blockage, clean if necessary. If the inlet is blocked/partly blocked by sticky dust/particles open the inspection panel on the top off the unit and clean the preseparator. 7

28 A valve is not operating correctly (but there are functioning valves). F Does the display on the control box show ERR + a digit? YES NO Is the air temperature below C? IMPORTANT! Turn off the compressed air supply with the service valve (accessory) before doing any work on the cleaning system. G Go to B NO YES Leaking compressed air system (notified by sound) Check which valve is malfunctioning by listening. The valve sequence is, 5, 6,,, (where is to the left when the door has been opened). Dismantle the valve housing and check that the little air hole in the diaphragm not is blocked. Change defective valves (spare part) or repair them with a repair set (spare part). Mounting/repairing instructions comes with the spare parts. If you have compressed air with a dew point close to or higher then the air temperature, the pilot valve may freeze. An indication is that the valve starts operating again when the temperature increases. IMPORTANT! Do not pressurise the system if the temperature is below the minimum operating temperature (= - C). At lower air temperatures the process can be started and operated for a while (approx. 5 min.) whereafter the system can be pressurised. Are the external connections leaking? YES NO Stop the system. Decrease the system pressure to < bar. Open the access door and find the leak. Repair the external connections. Shut off the pressure and drain the tank. Is a pulse-jet valve leaking? YES NO Replace other damaged parts. H High emission. Abnormal emission levels in the exhaust air. Dismantle the valve and check for contamination or damaged parts. Clean and/or replace damaged parts. Stop the system! Shut off the compressed air and drain the tank. Are all cartridges properly installed? NO YES Install them properly. Look into the cartridges and check if there are any traces of dust. Dust on the clean side indicates a leak. Replace damaged cartridges. 8

29 SPARE PARTS Ordering Instructions When ordering spare parts always indicate the following. A. Part No. and Control No. (see FilterMax identification plate) B. The spare part s name and number (see Spare Parts List) C. Quantity of parts required. 8 Spare Parts List Name Filter cartridge Basic (6-pack) High efficiency (6-pack) Circuit card (monitoring system) Control box, complete incl. electric components Repair set for valve 5 Pulse valve 6 Door switch 7 Cleaning pipe 8 Cover with display 9 Transformer Circuit card (pilot box) Pilot valve Deflector sheet Inlet Ø 5 Inlet Ø 5 Inlet Ø Inlet Ø 5 Outlet Ø 5 Outlet Ø Outlet Ø 5 5 Acceleration nozzle 6 Pilot box, complete 7 Dust container 8 Door gasket

30 ACCESSORIES NCF FANS See fan diagram page 5. For more information contact your nearest Nederman representative. SOUND-ABSORBING HOUSING FOR NCF FANS For more information contact your nearest Nederman representative. FAN STARTER Consists of a contactor and an Y/D-start. To be connected together with the after cleaning damper in a way that stops the fan when the damper has been closed. For more information contact your nearest Nederman representative. FAN INVERTER Self regulating system, adjusts the air flow depending on the number of connected extractors and filter condition. Decreases the air sound level by regulating air flow to demand. Replaces fan starter (Y/D-start). Reduces the energy cost for the fan. Reduces the extraction of heated air which saves still more energy costs. For more information contact your nearest Nederman representative. SAFETY SWITCH FOR FAN To be used for service work on the fan. For more information contact your nearest Nederman representative. TIMER FOR FAN V AC/DC. For more information contact your nearest Nederman representative. PRESSURE SWITCH Part no. 7 PRESSURE SWITCH (Not a Nederman product). Is used to indicate low airflow or high fall of pressure over the filter. AFTER CLEANING DAMPER (Not a Nederman product) The damper closes the duct when FilterMax is shut off, which will prevent dust from being transported back into the workshop by the air pulses from the down time cleaning. The damper should be mounted close to the FilterMax inlet. ADVANCED CONTROL AND MONITORING SYSTEM Is used for controlling the cleaning more efficiently and with better supervision. Saves pressured air in some applications with intermittent load. Equipped with alarm functions as for example - high fall of pressure for filter, -low air flow, -high/low air temperature. Can be used for remote controlling maximum m from FilterMax. Is delivered with 5 m cable for connection to FilterMax control box. Part no. 76 FILTER REGULATOR Is used for setting the correct air pressure. Separates dust in the pressured air why it also protects the valves. Should be installed in the compressed air pipe line. Must be positioned in a frost free environment Part no. 76 SHUT OFF VALVE FOR COMPRESSED AIR An air venting type. Should be installed in the compressed air pipe line. Is used to turn off the compressed air supply before any service on the system is done. Part no. 78 PRESSURE GAUGE KIT Measures the pressure drop over the filter cartridges. Is mounted on the FilterMax stand. Can be combined with a pressure switch to get LED no. 5 indicated, which indicates time to change filter cartridges. Part no. 779 ESC OK 5 5 5

31 INSTALLATION PROTOCOL If controls give results (for example measured values) which differ much from earlier results, this must be understood as a warning signal and lead to more careful investigations. FilterMax No. Date Performed by Control points Result Result Result Note. Delivery control (page ) A. Missing components B. Transport damage. Installation control (page, 6-7) A. Safe mounting / foundation B. Fixing bolts / Traction forces C. Wind / Snow load D. Weight FilterMax DX / collected dust E. Conductible screw fittings F. Inlet and Outlet G. Dust container or Dust feeder H. ( or filter units) J. Filter cartridges. Compressed air connection (page 8) A. Service valve B. Filter regulator C. Pressure switch D. Pressure, -,6 MPa E. Dew point F. Oil / Moisture G. Cleaning compressed air connections. Duct dimensioning (page 6) A. Duct diameters B. Inlet duct, length/inclination C. Cleaning access covers D. Fire damper E. After cleaning damper F. Flow meter G. NCF fan H. Extraction arms

32 INSTALLATION PROTOCOL FilterMax No. Date Performed by Control points Result Result Result Note 5. Electrical installation (page 9-5) A. Overload protector B. Safety switch, EX-proofed C. After cleaning damper D. Pilot box (, or ) E. Fan F. Fan Starter G. (Extern START/STOP) H. (Pressure switch, compressed air) J. (Pressure switch, high dp/low airflow) K. (Pressure switch, simple dp control) L. (Explosion / Fire alarm) M. (Dust feeder) N. Sum alarm, alarm signal devices O. A-alarm P. Activating, in/outputs Q. (Line-connection, page ) 6. Earth control measurement (page ) A. GND - Inlet B. GND - Inlet cleaning access cover C. GND - Dust container D. GND - Dust container adapter E. GND - Filter cartridges F. GND - Filter units G. GND - Doors 7. Monitoring system, settings (page 8-9) A. Cleaning during operation B. Pause time setting C. Cleaning after operation D. A-alarm function E. Remote control

33 SERVICE PROTOCOL (page, - 5) FilterMax No. Date Operating hours Performed by Control points Result Result Result Result Result. Dust container / Filter regulator A. Empty the dust container (when 7 % full) B. Water check filter regulator C. Water check pressure tank. Magnetic valves, function check. Remove dust, clean air room every h * every h * every 6 h *. Cleaning access covers, cleaning 5. Water check pressure tank 6. Checking the filter cartridges 7. Remove corrosion by grinding, primer and touch up paint 8. Earth control measurement (page ) A. GND - Inlet B. GND - Inlet cleaning access cover C. GND - Dust container D. GND - Dust container adapter E. GND - Filter cartridges F. GND - Filter units G. GND - Doors 9. Replacing the filter cartridges (page 5). Check that the cables not are damaged or connected incorrectly *Every hours or at least once every 6th month. Every hours or at least once a year or when replacing filter cartridges. Every 6 hours or at damage or insufficient filter function.