Installation and service manual FlexPAK Series FlexPAK 800/1000 DX Models Original installation and service manual EN Installation and service MANUAL 2014-03-04 144885(01)
2 FlexPAK 800/1000 DX
Figures...4 English...19 3
FlexPAK 800/1000 DX Figures 1 Type Art.no 50 Ser.no Hz V A kw 60 Hz V A kw hp Year of manufacture Y AB Ph Nederman & Co SWEDEN 2A 4 1019 mm (40.1") 58 mm (2.3") 772 mm (30.4") 2116mm (83.3") 45 1670mm (65.8")
FlexPAK 800/1000 DX 2B 80mm (3.25") 120mm (4.8") 1010mm (40") 1650mm (65.0") 2116mm (83.3") 1750mm (69") 2C 98 98 98 98 98 98 320 90 88 220 90 (mm) 18x O 14 540 640 5
3 A B 4A 5 6 4 3 7 8 9 10 2 11 12 1 13 6
FlexPAK 800/1000 DX 4B 18 7 16 8 17 9 10 11 15 12 13 14 4C 19 20 21 7
5 1 2 3 4 5 6 =TR1 =F2 =F3 1-80 Standby/ Running Service Fault Filter Cleaning Test Start =F4 =F5 12 11 10 9 8 7 67 A B 8
8 2 6 1 SIEMENS Stop Set Param Set >Prg Name LOGO! 12/24RC XXXXXXX-XXXXX-XXXX 5 3 4 9
9 4 5 6 7 8 10 1 9 2 11 3 10 1643±1mm (65 ) 1771.4±1mm (70 ) 662±1mm (26.2 ) Ø13mm 1 10
111212 13 14 11
15 Min > 2.1m (83") A C A A A 161717 1.5m (59") A B C 12
18 Circuit Diagram FlexPAK 800-1000 Loggo PLC (DU1) and Frequency Converter (UE1) 13
19 Circuit Diagram FlexPAK 800-1000 Digital I/O Extension Modul (DU2) 14
20 Circuit Diagram FlexPAK 800-1000 PT100 Extension Module (DU3) 15
FlexPAK 800/1000 DX 21 Circuit Diagram FlexPAK 800-1000 Layout Terminal X1 and Frequency Converter (UE1) 16
17 22 22
23 1 Nederman FlexPAK Off TimeToSerTo vice 2000Hour PS Pilot Signal Off PS Pilot Signal On 2 FlexPAK Off Standby TimeToSerTo vice 2000Hour PS 3 Running kpa -20 DIRTm 10:00s OTTmr 00:00s PS DIR_Time DIR_Time T < 10:00s Ta = 00:00 T > 10:00s Ta = 00:00 4 FlexPAK Idling TimeToStandbTo y 00:12m PS SSR_Time SSR_Time T > 12:00m Ta = 00:00 T < 12:00m Ta = 00:00 18
EN English Installation and service manual Table of contents Figures... 4 1 Preface...22 2 Notices...22 3 Description...22 3.1 Function...22 3.2 FlexPAK 800/1000 DX and ATEX...23 3.2.1 Permitted materials...23 3.3 Explosion protection...23 3.3.1 Explosion venting...24 3.3.2 Explosion suppression system...24 3.3.3 Flameless venting...24 3.3.4 Isolation device...25 3.4 Dimensions...25 3.5 Technical data...25 3.6 Fuses...26 3.7 Main components...26 3.8 Start and control unit...27 3.9 Frequency converter...27 4 Accessories...28 5 Installation...28 5.1 Delivery check...28 5.2 Installation requirements...28 5.2.1 Bolts...29 5.3 Duct dimensions and installation...29 5.3.1 Requirements...29 5.3.2 Recommendations...29 5.4 Installing the unit...30 5.4.1 Indoor installation...30 5.4.2 Outdoor installation...30 5.4.3 Moving the unit...30 5.5 Connections...31 5.6 Electrical installation...31 5.7 Suppression system installation...32 5.8 General requirements...32 5.9 Ground check measurement...32 5.10 Compressed air installation...33 5.10.1 Requirements...33 5.10.2 Installation...33 6 Using the unit...33 6.1 Before initial start-up...34 6.2 Initial start-up...34 6.2.1 Checking the filter cleaning function...34 6.2.2 Checking the automatic start and stop function...34 6.3 Unit operation...35 19
EN FlexPAK 800/1000 DX 6.3.1 Starting the unit... 35 6.3.2 Unit operation modes... 35 7 PLC messages... 36 7.1 Status messages... 36 7.1.1 Nederman FlexPAK DX Off (Off mode)... 36 7.1.2 FlexPAK DX Standby (Standby mode)... 36 7.1.3 Running (Running mode)... 36 7.1.4 FlexPAK DX Idling (Idling mode)... 36 7.1.5 Filter Cleaning... 37 7.2 Status messages: Accessories, customer connections... 37 7.2.1 Emptying preseparator... 37 7.2.2 Open Upper Slide Valve V12... 37 7.2.3 Close Upper Slide Valve V12... 37 7.2.4 Open Lower Slide Valve V11... 37 7.2.5 Close Lower Slide Valve V11... 38 7.2.6 Flushing duct... 38 7.3 Warning messages... 38 7.3.1 Time For service... 38 7.3.2 Main Filter Clogged... 38 7.3.3 Dustbin Full... 39 7.3.4 Bag Replacement Switch Activated... 39 7.4 Alarms... 39 7.4.1 External Fire Alarm Explosion Detected... 40 7.4.2 Frequency Conv Alarm... 40 7.4.3 PTC Detect Hi Motor Temp Unit Shut Down... 40 7.4.4 Low Pressure... 40 7.4.5 Hi Vacuum... 40 7.4.6 Exhaust Air Temp High... 41 7.4.7 Bag Replacement Switch Time Out... 41 7.4.8 Control Filter Clogged... 41 7.4.9 TVFD Error! Upper Slide Not Closed... 41 7.4.10 TVFD Error! Upper Slide Not Open... 41 7.4.11 TVFD Error! Lower Slide Not Closed... 42 7.4.12 TVFD Error! Lower Slide Not Open... 42 7.4.13 TVFD Error! Slides In Open Position... 43 8 PLC settings... 43 8.1 Find a parameter and set its value... 43 8.2 Parameter settings... 44 8.2.1 Adjust the time and date... 44 8.2.2 Weekly timer... 45 8.2.3 H-Meter 1... 46 8.2.4 DIR_Time... 46 8.2.5 SSR_Time... 46 8.2.6 FltClean... 47 8.2.7 ClenCyl... 47 8.3 Parameter settings: Accessories, customer connections... 47 8.3.1 MFDPS-FC... 47 8.3.2 MFDPS-Wr... 47 8.3.3 DPFClean... 47 8.3.4 OTTmr... 48 8.3.5 CFDPS-Al... 48 8.3.6 PSIFC... 48 8.3.7 FlushTmr... 49 8.3.8 PSCFlush... 49 8.3.9 FlushCy1... 49 8.3.10 FlushCy2... 49 8.3.11 FlushTMP activation... 49 8.3.12 FlushTmp... 50 8.3.13 CoolTmp... 50 8.3.14 CoolTmr... 50 20
EN 8.3.15 BRSTmr... 51 8.3.16 AEBTme... 51 8.3.17 BinAuto... 51 8.3.18 BLI-Wr... 51 8.3.19 BLI-Empt... 52 8.3.20 LiAuto... 52 8.3.21 AEB-TVFD... 52 8.3.22 BinOpnTm... 52 8.3.23 EmtyIdli... 53 8.3.24 TVFDAdv... 53 8.3.25 TVFDO-Al... 53 8.3.26 TVFDC-Al... 53 8.3.27 LSOTmr... 53 8.3.28 Presep... 54 8.3.29 PresepTm... 54 9 Automatic bin emptying function... 54 9.1 AEB-Flap Valve settings... 54 9.1.1 Hardware... 54 9.1.2 PLC Settings... 54 9.1.3 Timer Settings... 54 9.2 Simple TVFD Valve Settings... 54 9.2.1 Hardware... 54 9.2.2 PLC Settings... 55 9.2.3 Timer settings... 55 9.3 Pre-Separator Settings... 55 9.3.1 Hardware... 55 9.3.2 PLC Settings... 55 9.3.3 Timer settings: Pre-Separator 1... 55 9.3.4 Timer settings: Pre-Separator 2... 55 9.4 Advance TVFD Valve Settings... 55 9.4.1 Hardware... 55 9.4.2 PLC Settings... 56 9.4.3 Timer settings... 56 10 Machining chips and swarf extraction... 56 10.1 Electrical connection of indicator lamp... 56 11 Pneumatic filter cleaning valve... 56 11.1 Filter cleaning button... 56 11.2 Filter cleaning in Standby mode... 56 11.3 Filter cleaning in Running mode... 57 11.4 Filter cleaning valve function... 57 11.5 Compressed air switch function (accessory)... 57 12 Maintenance... 57 12.1 Service and maintenance of ATEX equipment... 58 12.2 Checks one month after installation and every year... 58 12.3 Empty the collector bin... 59 12.4 Replace main filter... 59 12.5 Change control filter... 60 12.6 Check the filter cleaning function... 60 12.7 The motor and the fan unit... 60 12.8 Cooling filter for the frequency converter... 61 12.9 Loading new software... 61 12.9.1 Frequency converter control panel... 61 12.9.2 Firmware and software labelling... 61 12.9.3 Upgrading the system... 61 12.10 Spare parts... 62 13 Recycling... 62 13.1 Environmental information... 62 14 Troubleshooting... 62 21
EN FlexPAK 800/1000 DX 14.1 Tools... 62 14.2 Remove the lid of the start and control unit... 62 15 Acronyms and abbreviations... 65 Appendix A: Installation protocol...66 Appendix B: Service protocol...68 1 Preface This manual is for the correct installation, use and maintenance of this product. Read it carefully before using this product or carrying out maintenance. Replace the manual immediately if lost. This product has been designed to meet the requirements of relevant EC directives. To maintain this status, all installation, repair and maintenance work for this product is to be carried out by qualified personnel using only Nederman original spare parts. Contact the nearest authorized distributor or Nederman for advice on technical service and obtaining spare parts. Nederman continuously improves its products design and efficiency through modifications, and reserves the right to do so without introducing these improvements to previously supplied products. Nederman also reserve the right to, without previous notice, modify data and equipment as well as operating and maintenance instructions. 2 Notices This document contains important information that is presented either as a warning, caution or note. See the following examples: Warning! Type of injury. Warnings indicate a potential hazard to the health and safety of personnel, and how that hazard may be avoided. Caution! Type of risk. Cautions indicate a potential hazard to the product but not to personnel, and how that hazard may be avoided. Note! Notes contain other information that is important for personnel. 3 Description 3.1 Function FlexPAK 800/1000 DX has been designed to filter combustible and non-combustible dust and welding fumes in a high vacuum system. FlexPAK 800/1000 DX is a complete vacuum unit with a direct driven side channel fan fitted as one unit on a steel frame and a start and control unit with an integrated 24 V transformer. The unit is controlled by a frequency converter, has automatic start/ stop, and automatic filter cleaning. Filtration in two stages FlexPAK 800/1000 DX filters particles in two stages. In the first stage, coarse particles are separated away in the inlet. In the second stage, fine particles are separated away by filter bags, see figure 9. Automatic filter cleaning FlexPAK 800/1000 DX uses filter cleaning by a short blast of reversed air flow with atmospheric pressure. By the rapid opening of the Filter Cleaning Valve (FCV) located on top of the filter, a 22
EN powerful blast of reversed air flow is created, efficiently dislodging dust from the filter bags, see figure 8. Control filter The unit is equipped with a control filter, see figure 4B, item 16. The control filter filters the air after the main filter to ensure that no material continues to the suction source in case of a main filter breakage. The control filter functions as a safety device and does not increase the filtration efficiency. The pressure drop over the control filter is monitored, and a signal is sent to the control unit if the pressure difference reaches the set value. The pressure difference is preset at 4 kn Pa /40 mbar / 0.58 PSI. 3.2 FlexPAK 800/1000 DX and ATEX FlexPAK 800/1000 DX is designed to extract combustible and noncombustible dust, but the unit as a whole is not to be placed in an area that is classified as a zone according to directive 1999/92/EC. It is only the inside of the filter that meets ATEX requirements. FlexPAK 800/1000 DX may be used with duct systems internally classified as zone 20, 21 or 22. The product has no marking since there is no internal ignition source. The inside is to be considered a simple filter/silo and does not fall under the scope of the directive 94/9/ EC.* *Source: ATEX working group considerations; How should the directive be applied to filter units and vented silo bins. 3.2.1 Permitted materials Note! It is of the utmost importance to know the properties of the extracted material. FlexPAK DX is intended to be a part of an extraction system collecting material with the following properties: MIE (Minimum Ignition Energy) > 3 mj. MIT (Minimum Ignition Temperature) > 205 ºC. Kst: See the product identification plate. Pmax: See the product identification plate. Materials with properties not within the values stated above or if a suppression or flameless system is used are to be investigated prior to use with FlexPAK 800/1000 DX. Contact Nederman for technical support and dust application investigation. Warning! Explosion risk. Do not collect material that may cause ignition or blocking. It is strictly prohibited to collect material that may undergo dangerous chemical or thermal reactions and/or self-ignite. Warning! Explosion risk. Do make any changes to this product without consulting Nederman. Adding a relief duct or changing the spacing or length of filter elements affects the calculations according to EN 14491. Note! Some materials may undergo chemical reactions in combination with humidity/water. Such humidity may, for example, form if the humidity in the extracted air is condensed in the filter. Warning! Risk of personal injuries. Use suitable protective equipment: goggles, ear protection and a protective mask. 3.3 Explosion protection The CE and ATEX markings on this unit ensure both a high level of safety and protection against ignition of the collected combustible dust. However, if an explosion occurs due to misuse, insufficient maintenance or faulty installation, this unit is equipped with additional protection methods to avoid dangerous pressure build-up in the filter. FlexPAK 800/1000 DX is equipped with one of the following protection systems. 23
EN FlexPAK 800/1000 DX Explosion venting, see figure 2A. Explosion suppression system, see figure 2B. 3.3.1 Explosion venting The harmful effects of an explosion are minimized by venting the pressure and flame of the explosion through an explosion relief panel, see figure 2A. In case of an explosion, the resulting flame and pressure escape through the explosion relief panel which is to be directed towards a safe area without any people. This area is referred to as the risk area. The risk area is to be clearly marked, for example with a fence, warning lines and signs, and entry is prohibited when the filter is in operation. The area is to be free of any flammable or combustible material or other objects which may be damaged by the flames and explosion pressure. The general size of the risk area is shown in figure 3. The following dimensions apply: A = 10 m (32.8 ft) B = 5 m (16.4 ft) NOTE! The risk area may extend beyond the values given above. The final risk area is to be evaluated with regards to affecting factors found in Standard EN 14491. In some cases, it is necessary to use a duct on the explosion relief panel to vent the flame and pressure to a proper safe area. Such a duct is to be at least 0.1 m (0.33 ft) larger than the relief panel outer dimensions, and be able to withstand an overpressure of at least 0.5 bar (5.8 PSI). Note! For assistance and information, contact Nederman. 3.3.2 Explosion suppression system With an explosion suppression system, the early stage of an explosion is detected with optical and/ or pressure-sensitive devices, and an extinguishing agent is quickly dispersed into the filter, see figure 2B. The suppression of the explosion is initiated an extremely short time after detection of the explosion (in milliseconds), and stops the pressure rising and extinguishes (suppresses) the flames of the explosion. This ensures that the filter is not stressed to a dangerous level by the explosion. The key components of the explosion suppression system are the following: An explosion detection device (optical/pressure-sensitive). A computer-operated control unit. Action elements such as pressure cylinders containing an extinguish agent with an extra fast opening valve. Detailed information regarding system installation, function, operation and maintenance can be found in the suppression system manual. 3.3.3 Flameless venting The method of flameless venting is similar to method 1 explosion venting. However, a device attached to the outside of the vent will stop flames from exiting the filter vessel. Such a device is sometimes referred to as a quench-device or flameless-device. Common for all types of flameless devices is that the explosion is released through a specially designed grid or mesh. The grid or mesh will allow pressure from an explosion to be released, but prevent the explosion s flames from exiting outside the filter vessel. The benefit of using a flameless vent device is that it reduces the size of the risk area. This increases the possibility of positioning the FlexPAK 800/1000 DX closer to manned areas or equipment. However, it must be noted that the use of a flameless device does not eliminate the risk area. The high pressure and hot gases are still released into the surroundings, and this must be taken into consideration when positioning the FlexPAK 800/1000 DX. Please consult your local fire authority when determining suitable positioning of the FlexPAK 800/1000 DX with flameless device. 24
EN Please refer to the installation and service or user manual for the flameless device supplied with the FlexPAK 800/1000 DX to find other limitations and information regarding safe use and service. The use of a flameless device will also reduce the venting efficiency of the FlexPAK 800/1000 DX. This means that the FlexPAK 800/1000 DX will not be able to be used with explosive dust types with a higher Kst (ST type). The limit of the Kst value (ST type) is determined by the parameters of the specific flameless device. 3.3.4 Isolation device An isolation device, see figure 9, item 2, is to be installed to prevent a filter explosion from propagating back into the plant through the connected duct. The duct, see figure 9, item 3, between the unit and the isolation device is to be pressure-resistant to an overpressure of at least 0.5 bar (7.2 PSI) and have a minimum length as specified in the manual of the isolation device. This is normally 4 meters for ST2 and 2 meters for ST1. 3.4 Dimensions For the dimensions of FlexPAK 800/1000 DX, see figures 2A, 2B, and 2C. Note! Figure 2D shows the dimensions of the inlet and one side of FlexPAK 800/1000 DX. 3.5 Technical data Table 3-1: Technical data FlexPAK 800 DX FlexPAK 800 DX Effect 18.5 kw (25 hp) 18.5 kw (25 hp) 21.5 kw (29 hp) Mains voltage/frequency 230 V±10%/50 60 Hz 400 V±10%/50 60 Hz 460 V±10%/50 60 Hz Maximum flow 1,300 m 3 /h (765 cfm) 1,300 m 3 /h (765 cfm) 1,300 m 3 /h (765 cfm) Flow at -20 kpa 800 m 3 /h (470 cfm) 800 m 3 /h (470 cfm) 800 m 3 /h (470 cfm) Maximum vacuum -35 kpa (-5.1 PSI) -35 kpa (-5.1 PSI) -35 kpa (-5.1 PSI) Filter area 6 m 2 (64.5 sqft) 6 m 2 (64.5 sqft) 6 m 2 (64.5 sqft) Weight 439 kg (968 lb) 439 kg (968 lb) 439 kg (968 lb) Inlet/outlet diameter (flanged) 150/160 mm (7.87/6.29") 150/160 mm (7.87/6.29") 150/160 mm (7.87/6.29") Sound level 70 db(a) 70 db(a) 70 db(a) Filtration efficiency* Dust class L Dust class L Dust class L Maximum ambient temperature -10 +40 C (14 104 F) -10 +40 C (14 104 F) -10 +40 C (14 104 F) Relative humidity Max. 85% Max. 85% Max. 85% Compressed air 6 7 bar (87 102 PSI) 6 7 bar (87 102 PSI) 6 7 bar (87 102 PSI) Material recycling 93.6% per weight 93.6% per weight 93.6% per weight Control Filter area 1x12 m² (1x129 sqft) 1x12 m² (1x129 sqft) 1x12 m² (1x129 sqft) Control Filter material Polyester Polyester Polyester * According to DIN EN/IEC 60335-2-69. 25
EN FlexPAK 800/1000 DX Table 3-2: Technical data FlexPAK 1000 DX FlexPAK 1000 DX Effect 18.5 kw (25 hp) 18.5 kw (25 hp) 21.5 kw (29 hp) Mains voltage/frequency 230 V±10%/50 60 Hz 400 V±10%/50 60 Hz 460 V±10%/50 60 Hz Maximum flow 1,300 m 3 /h (765 cfm) 1,300 m 3 /h (765 cfm) 1,300 m 3 /h (765 cfm) Flow at -15 kpa 1000 m 3 /h (588 cfm) 1000 m 3 /h (588 cfm) 1000 m 3 /h (588 cfm) Maximum vacuum -20 kpa (-2.9 PSI) -20 kpa (-2.9 PSI) -20 kpa (-2.9 PSI) Filter area 6 m 2 (64.5 sqft) 6 m 2 (64.5 sqft) 6 m 2 (64.5 sqft) Weight 439 kg (968 lb) 439 kg (968 lb) 439 kg (968 lb) Inlet/outlet diameter 150/160 mm (7.87/6.29") 150/160 mm (7.87/6.29") 150/160 mm (7.87/6.29") Sound level 70 db(a) 70 db(a) 70 db(a) Filtration efficiency* Dust class L Dust class L Dust class L Maximum ambient temperature -10 +40 C (14 104 F) -10 +40 C (14 104 F) -10 +40 C (14 104 F) Relative humidity Max. 85% Max. 85% Max. 85% Compressed air 6 7 bar (87 102 PSI) 6 7 bar (87 102 PSI) 6 7 bar (87 102 PSI) Material recycling 93.6% per weight 93.6% per weight 93.6% per weight Control Filter area 1x12 m² (1x129 sqft) 1x12 m² (1x129 sqft) 1x12 m² (1x129 sqft) Control Filter material Polyester Polyester Polyester * According to DIN EN/IEC 60335-2-69. 3.6 Fuses Table 3-3: Fuses Fuse Size Type Main fuse F1, 230 V 65 A Slow mains fuses Main fuse F1, 400 V 35 A Slow mains fuses Main fuse F1, 460 V 40 A Slow mains fuses Transformer, primary fuse F2 and F3 6 A Slow fuses, 10.3 38 Transformer, secondary protection PTC resistor F4 50 ma Fast, 5 20 F5 1 A Slow, 5 20 3.7 Main components Figures 4A, 4B and 4C show the main components of the unit: 1. Collector bin, see figure 4A. Note! Never use the unit without an antistatic plastic bag. Use Nederman original bags only. 2. Dust extractor, see figure 4A. 3. Textile filter bags, see figure 4A. 4. Filter holder, see figure 4A. 5. Filter Cleaning Valve (FCV), see figure 4A. 6. Connection duct from the dust extractor to the inlet silencer, see figure 4A. 7. Start and control unit, see figures 4A and 4B. 8. Control panel, see figures 4A and 4B. 9. Frequency converter, see figures 4A and 4B. 10. Emergency switch, see figures 4A and 4B. 11. Frequency converter cooling air filter, see figures 4A and 4B. 12. Cooling valve, see figures 4A and 4B. 13. High pressure side channel fan, with pump characteristic, see figures 4A and 4B. 14. PT100 sensor, see figure 4B. 26
EN 15. Outlet silencer after fan, see figure 4B. 16. Control Filter and filter cartridge, see figure 4B. 17. Pressure sensor, see figure 4B. 18. Acoustic enclosure, see figure 4B. 19. Cooling air hose from the frequency converter, see figure 4C. 20. Compressed air supply, see figure 4C. 21. Inlet, see figure 4C. Note! Depending on the FlexPAK 800/1000 DX, there is also an explosion protection device, see figures 2A and 2B. See also section 3.3 Explosion protection. Warning! Risk of personal injury. Depending on the FlexPAK 800/1000 DX model used, treat its explosion protection device carefully so that it does not become damaged, see figure 2. 3.8 Start and control unit The unit has a start and control unit, see figure 5. The start and control unit has the following components: 1. Transformer TR1, 60 W. 2. Connection block for the transformer TR1. 3. Transformer primary fuses F2 and F3, 6 A, slow. 4. Programmable Logic Controller (PLC). 5. Data Unit 2 (DU2), I/O module. 6. AM 2 PT100, temperature sensor input expansion module. 7. Filter cleaning/test start button. 8. Standby/Running button, which is the On/Off button. 9. Terminals: X1: 1-80. 10. Fuse for 24 V DC accessory supply. Fuse F5, 1 A, slow. 11. Fuse for Pilot Signal (PS) cable. Fuse F4, 1 A, fast. 12. Terminals Protective Earth (PE). 3.9 Frequency converter Warning! Risk of electric shock. The frequency converter is not to be opened until 5 minutes after the supply voltage has been disconnected. The capacitors inside the converter hold a very dangerous voltage until they have discharged themselves. Caution! Risk of equipment damage. No parameters in the frequency converter may be adjusted without very detailed knowledge about the consequences. Adjustment voids the warranty. Caution! Risk of equipment damage. The unit is not to be started if the cooling hose has been removed. The frequency converter controls the unit s motor so that it operates efficiently, as well as maintaining the unit s vacuum level to help prevent a dangerous underpressure from developing. The manual for the frequency converter is enclosed. Note! Figures 4C and 6 show the cooling air hose that improves the cooling of the frequency converter. Note! For parameter settings in the frequency converter, see the FlexPAK Frequency Converter Parameter Table that is a separate document included with the unit. 27
EN FlexPAK 800/1000 DX 4 Accessories The installation of Nederman accessories for FlexPAK 800/1000 DX is described in the manuals for each product. Consult your local Nederman representative for available accessories. The FlexPAK 800/1000 DX start and control unit is prepared for the connection of accessories and customer connections. Accessories and extra equipment and functions are connected according to figures 19, 20 and 21. The most common accessory is a PS cable, which allows remote start/stop signalling from the valves on the duct system. See also Chapter 7 PLC messages and Chapter 8 PLC settings for more information about messages and settings for accessories, and customer connections. 5 Installation Warning! Risk of personal injuries. Use proper lifting and protective equipment. Warning! Risk of tipping. Consider the centre of gravity during transportation. Note! Always follow local laws and regulations for all steps in the installation process. NOTE! Fill in the installation protocol during installation, see Appendix A: Installation protocol. NOTE! Make a layout for the entire system before installing the unit. Note! The unit is to be anchored to the floor, particularly if it is located at a high level, to ensure that it does not move and fall down. The frame has four holes for anchoring. Take care during relocation and transport of the unit to avoid tipping. If the unit is to be moved, the frame is to be attached to the front of the bottom frame, see figure 10, item 1. Note! Some types of dust may cause a dust explosion and/or fire. Before installation, investigate whether the dust to be collected by the system constitutes a risk. Any risk can affect the choice of location and may, in some cases, result in the need to modify the unit. The choice of ducting may significantly influence the risk of a dust explosion, see Section 5.5 Connections. Note! We recommend that fire alarms and appropriate extinguishing systems are to be installed at all locations where collected combustible dust is stored. Note! Standards relating to the connection and use of filters in hazardous areas are to be taken into consideration, especially national standards for installation. Only trained personnel familiar with these standards is allowed to handle this type of filters. Note! The designer of the system as a whole, has to guarantee the correct function of all interacting products or components and ensure that the complete system meets all necessary safety requirements. 5.1 Delivery check Check the unit for any transport damage. In case of damage or missing parts, notify the carrier and your local Nederman representative immediately. 5.2 Installation requirements Prepare the location where FlexPAK 800/1000 DX is to be placed before installation. Consider the following when installing the unit: The unit is to be anchored to a hard, level and firm foundation. There are four fastening brackets on the bottom frame to be used to fasten the unit to the raised foundation. The total weight of the unit with accessories. Traction forces generated by explosion relief venting, see section 5.2.1 Bolts. Maximum weight of the collected material. Do not install the unit close to heat sources or hot surfaces. Beware of hot air from the outlet. 28
EN 5.2.1 Bolts Ensure that handling is convenient. Ensure that emptying collected dust is convenient. Ensure that service and maintenance are convenient. In case of high relative humidity, do not expose the unit to freezing temperatures. Do not place the unit in direct sunlight. Each of the anchor bolts securing the unit is to withstand traction forces of 6.5 kn vertically and 2.5 kn horizontally. See also figure 10. Recommended bolts for concrete are Hilti HDA-PF 20-M10 100/20. If expansion bolts are to be used, the concrete foundation is to be prepared according to bolt recommendations. 5.3 Duct dimensions and installation Figure 9 shows the unit installation in a typical vacuum duct system. 5.3.1 Requirements Place a sign with the intended use of the vacuum system on every user interface (workstation). Inform all personnel of the intended use of the system. Ensure that personnel using the equipment do not collect items that may cause ignition or blocking, also see 3.3.4 Isolation device. NOTE! All connected ducts are to be conductive and grounded. Warning! Explosion risk. The ducting is to be built with plain steel pipe. Plastic pipe, such as PVC, is not to be used. Almost all types of dust pick up static electricity when sucked though a plastic pipe, which significantly increases the risk for an explosion if the dust is explosive. Warning! Explosion risk. Do not collect material that may cause ignition or blocking. It is strictly prohibited to collect material that may undergo dangerous chemical or thermal reactions and/or self-ignite. Warning! Explosion risk. Some types of dust may cause a dust explosion and/or fire. Before installation, investigate whether the dust to be collected by the system constitutes a risk. Risk of equipment damage. The silencer outlet for exhaust air is to be directed upwards. Fit a Spiro duct to direct the exhaust into the atmosphere. The duct is to be routed to prevent any particles from falling into the unit, which could cause serious damage Note! Self-ignition can occur with some types of dust. Under no circumstances may magnesium and titanium dust be sucked into the system. Accumulated welding fumes from ordinary steel welding do not self-ignite, but they can be ignited by, for example, a cigarette sucked into the system. A fire in accumulated welding fumes does not spread quickly but it is hard to extinguish. 5.3.2 Recommendations Transport velocity It is important to use the correct duct diameter to avoid pressure losses and dust deposits in the duct system. Ensure that the correct transport velocity is achieved. Correct velocity depends on the properties of the transported material. Some applications may require velocities up to 25 m/s (82 ft/s). Take velocity into account when choosing duct diameters. The velocity is never to decrease on the way to the unit. The transport velocity in the ducts may vary depending on how much of the vacuum system is used. Flushing Depending on the type of dust and fumes to be filtered by the unit, a principle called flushing may be used to keep the vacuum ducts clean. Flushing may be applied by fitting a valve at the end of the duct system. By not using the rest of the system, and opening the so called flush valve, a high 29
EN FlexPAK 800/1000 DX amount of air will flush the ducts clean. By flushing each branch of the vacuum system separately, the risk of dust deposits is minimized. In larger vacuum systems with multiple units installed, the installation of Duct Isolation Valves (DIV) is recommended in order to isolate one unit for maintenance while the others remain in normal operation. If the dust is abrasive, it may be necessary to use thick-walled (or rubber coated) material in bends and other exposed areas. To avoid pressure losses, the duct system is to be as short as possible and designed with two or more branches. Use larger diameters on the clean side to reduce pressure losses. 5.4 Installing the unit Note! For suppression units, detailed information regarding installation of an explosion suppression system can be found in the suppression system manual. Work is only to be carried out by certified personnel. Note! To minimize any secondary explosion damage and spread of fire, the proper documentation and checklists of how to handle a fire in the unit has to be developed. Such documents are to be developed in co-operation with the local fire authorities, and take into account the properties of the collected material. Warning! Risk of eye injuries. Always stop the unit before looking into the outlet. The fan rotates at high speed and debris and particles coming out of the outlet may cause eye injuries. 5.4.1 Indoor installation It is recommended that the unit is positioned indoors. Ensure that the room where the unit is to be installed is well ventilated. NOTE! Never completely seal a small room with the unit installed. NOTE! Make sure that the room where the unit is installed is well ventilated. Under some conditions, the unit may draw air directly into the high-pressure fan. This may cause a dangerous underpressure in the room if air cannot enter freely. There are to be two openings for ventilation, at least 250 250 mm (10" 10") in size. One is to be placed up high and the other one down low. The warm exhaust air is to be directed from the unit and out of the premises, see figure 9, item 4. Connect a duct that directs the exhaust air outdoors. The air can be directed to a heat exchanger, but there are not to be any dampers which may obstruct the air flow. Caution! Risk of equipment damage. If the exhaust air duct is blocked, the unit may create an overpressure, which may cause major damage to the heat exchanger. 5.4.2 Outdoor installation If installed outdoors, consider the following: The area needs to be protected from the weather. Cover the top of the unit to protect it from snow, rain or falling debris. Install a lightning conductor, see Section 5.8 General requirements. The ambient temperature is not to be below 0 C (32 F) or exceed 40 C (104 F). If the ambient temperature will less or greater than these limits, contact Nederman for more information about de-rating. 5.4.3 Moving the unit Warning! Risk of tipping. Consider the centre of gravity during transportation. 30
EN Warning! Risk of personal injury. Use proper lifting and protective equipment. If the unit is to be moved, the frame is to be attached to the front of the bottom frame, see figure 10, item 1. 5.5 Connections Equipment such as cables and hoses are not supplied and are to be obtained locally. Figure 9 shows the normal connections to the unit. They are as follows: 1. Duct from workstations. 2. Isolation device. 3. Pressure resistent duct between the unit and the isolation device. 4. Exhaust air duct, Ø 160 mm (for lengths <12 m). Note! The exhaust air duct is to be routed straight and as short a distance as possible. 5. PS cable from valves at workstations. 6. Incoming 3-phase power supply with a Protective Earth (PE) cable. 7. Compressed air supply, Ø 6 mm nylon hose. 8. Compressed air valve, size G1/4" or G1/2". 9. Water and dirt trap. Compressed air supply is to be clean and dry. 10. Maintenance switch according to standard. 11. Power cable to the unit. Note! The unit is CE-marked. Connections to the unit, initial start-up and maintenance are to be carried out according with this manual. 5.6 Electrical installation Warning! Risk of electric shock. Work with electric equipment is to be carried out by a qualified electrician. Warning! Risk of electric shock. The connected wiring system is to be electrically connected to the Potential Equalizing System (PES) on the premises. Note! The electrical connection is NOT to be equipped with an earth leakage circuit breaker when the frequency converter is provided with an EMC filter. The EMC filter function will make the earth leakage circuit breaker shut off power. Note! In accordance with the European standard, the incoming 3-phase supply is to be fitted with a hand-operated disconnecting device that conforms to the demands on disconnectors. The disconnecting device is to be fitted within 2 3 m from FlexPAK 800/1000 DX and be clearly visible from the unit. Refer to local and national standards when located outside of Europe. Note! Check the continuity of the protective current circuit before the unit is used. Note! Check that the supply voltage corresponds to the data on the machine plate of the unit, see figure 1, before connecting the unit to the mains supply. Note! Control that TR1, see figure 5, item 2, is connected to the correct voltage range. Note! Always replace worn, faulty or defect electrical components with new original parts. For the power circuit, control circuit and terminal connection diagrams, see the following figures: Loggo PLC (DU1) and Frequency Converter (UE1), see figure 18. Digital I/O Extension Module (DU2), see figure 19. PT100 Extension Module (DU3), see figure 20. Layout Terminal X1 and Frequency Converter (UE1), see figure 21. 31
EN FlexPAK 800/1000 DX 5.7 Suppression system installation Note! Information regarding installation of the active elements and control system can be found in the suppression system manual. Work is only to be carried out by personnel that are certified for installing suppression systems. Explosion detection signal from the suppression system must be connected to FlexPak DX terminal 42 43, see figure 21. Other suppression system signals must be taken into consideration and connected to suitable warnings and/or notification systems for the users. 5.8 General requirements The following items are minimum requirements to ensure the proper function and required level of protection with regards to equipment category, the EC directives and standards listed in Declaration of conformity : Take proper measures to avoid all types of electrical stray currents to and from the duct system and electrical wiring. Check that the input voltage and frequency to the unit are correct. A lightning conductor is to be installed if the unit is installed outdoors. The installation of the lightning conductor is to follow national and local regulations for such a protection device. 5.9 Ground check measurement Check that the unit is properly grounded after both the main installation and regular maintenance work. If a component is removed and refitted, ground connection is to be verified. Note! All metal parts of the unit are to be grounded. The system is to have two independent ground connections; one on the FlexPAK 800/1000 DX (GND1) and the other one on the duct system. Follow the procedure in To measure ground connection: below to ensure this. Ground connection is measured between GND1, see figure 19, terminal PE, and the following components on the unit: 1. Filter bags, see figure 4A, item 3. 2. Explosion suppression device, see figures 7 and 2A, 2B and 2C: 1) A screw on the explosion venting panel (7A). 2) The pipe of the explosion suppression device (7B). 3) A screw on the quenching device. 3. Inlet, see figure 4C, item 21. 4. Collector bin, see figure 4A, item 1. 5. Fan, see figures 4A and 4B, item 13. To measure ground connection: Note! The duct system (inlet and outlet) is NOT to be connected during measuring. 1. Disconnect mains ground from GND1. 2. Measure between all components according to the list above and GND1. The value is to be 100 ohm. 3. Measure and check whether there is contact between the incoming duct system and the disconnected incoming mains ground. The value is to be 105 ohm. 4. Connect the incoming duct system. Ensure that there is a second ground connection between the duct system and the unit and that it is properly grounded to the unit. 1) Measure and check whether there is contact between GND1 and the external mains ground ( 105 ohm). 5. Reconnect mains ground to GND1. 6. Connect the outgoing duct system. Ensure that there is ground connection between the duct system and the unit. 32
EN 5.10 Compressed air installation Warning! Risk of personal injuries. Use ear protection and safety goggles. Warning! Risk of personal injuries. The compressed air valve is to be locked in the closed position during maintenance. 5.10.1 Requirements For air consumption, quality and maximum and minimum pressure, see Sections 3.5 Technical data. NOTE! The specified air consumption of the unit is limited to the short operation of the cleaning valve. As new ducts may contain dirt, particles or debris, the compressed air pipe is to be blown clean before connecting the unit. A compressed air filter, see figure 9, item 9, is to be installed to ensure the reliable and safe operation of the unit. A compressed air valve, that vents the remaining pressure of the unit, is to be installed, see figure 9, item 8. NOTE! Take measures necessary to avoid water or humidity in the compressed air when the unit is installed in cold environments. NOTE! If antifreeze additives are used, use them continuously. Once added, the removal of the antifreeze additive may cause the pneumatic components to malfunction. 5.10.2 Installation Connect a compressed air supply to the inlet, see figure 4C item 20, and figure 9, item 7. Air pressure hoses are to be fitted together with electrical cables with straps, alternatively in a common protective hose. Air pressure hoses are to be anchored mechanically. NOTE! Secure the compressed air line properly. 6 Using the unit Warning! Explosion risk. Do not collect material that may cause ignition or blocking. It is strictly prohibited to collect material that may undergo dangerous chemical or thermal reactions and/or self-ignite. Do make any changes to this product without consulting Nederman. Adding a relief duct or changing the spacing or length of filter elements affects the calculations according to EN 14491. Clean the unit and the area around it of any spilled combustible dust before starting the unit Note! Some materials may undergo chemical reactions in combination with humidity/water. Such humidity may, for example, form if the humidity in the extracted air is condensed in the filter. Warning! Risk of personal injuries. Use suitable protective equipment: goggles, ear protection and a protective mask. A high vacuum system creates a powerful suction that may cause serious eye injury or hearing impairment. Persons who will be using FlexPAK 800/1000 DX, or may come in contact with FlexPAK 800/1000 DX, are to be informed about this risk. Never look into the exhaust air duct. Debris and particles coming out of the outlet may cause eye injuries. Use proper protective equipment when risking exposure to dust. Personnel operating FlexPAK 800/1000 DX are to pay special attention to avoiding discharge of static electricity. The requirements for the safe use and handling of combustible dust are described in the explosion protection document. All personnel are to be informed. Never operate the unit without an antistatic plastic sack in the dust bin if the dust is hazardous. The outlet silencer and fan may reach high temperatures during normal operation. 33
EN FlexPAK 800/1000 DX 6.1 Before initial start-up It is important that no dust, objects or debris are allowed to fall down into either the inlet or outlet of the side channel fan. The unit with its accessories are tested before delivery, and all functions are checked. Before initial start-up ensure the following: The maintenance switch has been installed, see figure 9 item 10. The room where the unit is located, if small, has adequate ventilation. See Section 5.4.1 Indoor installation. The ducting is connected to the dust collector inlet. An exhaust air duct is attached to the outlet to direct hot exhaust air away from the unit. Note! The unit is NOT to be operated under any circumstances without directing the exhaust air away from the unit. The compressed air supply is permanently connected. Idle mode and the filter cleaning will not work properly without a compressed air supply. The PS cable is connected, but no valves at work sites are open. 6.2 Initial start-up Warning! Risk of electric shock. Work with electric equipment is to be carried out by a qualified electrician. Unauthorized personnel may NOT remain in the vicinity of the unit when the control unit is open. Authorized personnel performing inspections and adjustments on the control equipment need to be careful to avoid electrical shocks. Remove the control unit lid since checks and adjustments in the control unit may be necessary during the initial start-up. (The PLC and the software are password-protected). Note! Always disconnect the supply voltage using the maintenance switch when performing inspections and adjustments. If the frequency converter has to be opened, wait 5 minutes after disconnecting power to avoid a static electric shock. The initial start-up is to be performed with the acoustic enclosure removed to verify the direction of rotation. Refit the acoustic enclosure when all checks have been performed. Note! Ensure that no valves at any workstations are open. 6.2.1 Checking the filter cleaning function When the unit is in Running mode, see Section 7.1.3 Running (Running mode), press the filter cleaning button, see figure 5, item 7, and check that the filter cleaning procedure starts. The filter cleaning function consists of the Filter Cleaning Valve (FCV), which is a pneumatic cylinder with a valve disc. The FCV is located at the top of the filter housing under the enclosure, see figure 8, item 6. A distinct change in sound can be heard as the valve releases atmospheric air into the filter, indicating that the function works properly. See also Section 3.1 Function. 6.2.2 Checking the automatic start and stop function Note! This procedure only works if default PLC settings are used. Press the Standby/Running button to put the unit into Standby mode. The unit is not to start until a valve is opened at a workplace activating its microswitch, or the test start/filter cleaning button is pressed, see the top of figure 8 and Section 11.3 Filter cleaning in Running mode. When the valve closes, the unit switches over to Idling mode and after a delay of approximately 10 seconds, a filter cleaning operation is performed. After an additional time delay of approximately 12 minutes, the unit will go into Standby mode. The filter cleaning delay is set by the DIR_time relay, and the stop delay is set by the SSR_time relay. 34
EN With all valves at the workstations closed, check that the motor slows down (a distinct change in sound can be heard), and that switching to Idling mode with filter cleaning takes place after approximately 10 seconds. Approximately 12 minutes after the unit has switched to Idling mode, it should go to Standby mode due to the SSR function switching off. 6.3 Unit operation 6.3.1 Starting the unit For more information regarding initial start-up, see Section 6.2 Initial start-up. Start the unit as follows: 1. Turn the maintenance switch to position 1, see figure 9 item 10. 2. Check that compressed air is connected to the unit. 3. Press the Standby/Running button on the control panel, see figure 5, item 8. The white lamp lights up and the display shows Standby. 4. The unit starts when the test start button is pressed, figure 5, item 7, or when a valve is opened at a workstation. Always switch off the unit at the end of the shift by pressing the Standby/Running button on the control panel, or use the weekly timer, see Section 8.2.2 Weekly timer. 6.3.2 Unit operation modes FlexPAK 800/1000 DX has the following four operation modes: 1. Off mode 2. Standby mode 3. Running mode 4. Idling mode See Section 7.1 Status messages for more information about each mode. How the unit moves from one operation mode to another is explained below. See also figure 23 for a flow chart showing how the unit goes through its four different operation modes. As discussed in Section 6.3.1 Starting the unit, when the unit is in Off mode, the unit can be put into Standby mode with its motor off and the Filter Cleaning Valve (FCV) closed by pressing the Standby/Running button. While the unit is in Standby mode, the unit can be put back into Off mode again by pressing the Standby/Running button. The unit goes from Standby mode into Running mode when it receives a pilot signal by a valve being opened at one or more work stations (in other words, someone starts to work). The unit s motor is now on and the FCV is closed. The DIR_Time and SSR_Time timers are not started, see Sections 8.2.4 DIR_Time and 8.2.5 SSR_Time. The unit stays in Running mode as long as there is an active pilot signal. However, the unit can still be put into Off mode by pressing the Standby/Running button. Note that if only one workstation is connected to the unit, or if only one work station is in use and work stops at that one station, the pilot signal stops. If there is more than one work station connected to the unit, and more than one work station is in use, the pilot signal only stops if work stops at all workstations (in other words, all valves close). When the pilot signal stops, the DIR and SSR timers start. If work resumes at one or more work stations within 10 seconds, the unit stays in Running mode. The DIR and SSR timers are reset back to zero and are stopped. If DIR_Time is set for 10 seconds (default), and the pause in work is longer than 10 seconds, DIR_ Time elapses. The unit then goes into Idling mode with its motor on and the FCV open. If a new pilot signal is sent within 12 minutes, the unit goes back into Running mode. The DIR and SSR timers are again reset to zero and are stopped. However, if SSR_Time is set for 12 minutes, 35
EN FlexPAK 800/1000 DX which is the default setting, and there is no new pilot signal within 12 minutes, SSR_Time also elapses. The unit then goes into Standby mode until it either receives a new pilot signal that puts the unit back into Running mode, or the unit is turned off (in other words, put into Off mode) by the weekly timer, see 8.2.2 Weekly timer, or by pressing the Standby/Running button. 7 PLC messages The following sections show the different status, warning and alarm messages that can be seen in the PLC display. 7.1 Status messages The following status messages give information about what mode the unit is in or what routine service is being performed. 7.1.1 Nederman FlexPAK DX Off (Off mode) The unit is in Off mode, which is also the unit s start menu. The unit can also go into Off mode if something is wrong, such as if an alarm is activated. The pump motor is off, there is no vacuum, the FCV is closed, and the unit cannot be activated by a pilot signal. Nederman FlexPAK Off TimeToService 2000Hour TimeToService: The amount of time until next scheduled service. The default setting is 2000 hours. See Section 8.2.3 H-Meter 1. 7.1.2 FlexPAK DX Standby (Standby mode) The unit is in Standby mode. The pump motor is off, there is no vacuum, the FCV is closed, and the unit is waiting for a pilot signal to go into Running mode. FlexPAK Standby TimeToService 2000Hour TimeToService: The amount of time until next scheduled service. The default setting is 2000 hours. See Section 8.2.3 H-Meter 1. 7.1.3 Running (Running mode) The unit in Running mode. The pump motor is on and the unit generates a vacuum. The FCV is closed. The current vacuum of the unit is shown on the display, for example, -20 kpa. Running kpa -20 DIRTm 10:00s OTTmr 00:00s DIRTm: The amount of time before the unit goes into Idling mode. The default is 10 seconds. See also Section 8.2.4 DIR_Time. OTTmr: If the Overtime timer has been activated, OTTmr shows the elapsed time since the overtime timer started. 7.1.4 FlexPAK DX Idling (Idling mode) The unit in Idling mode. The pump motor is on, there is no vacuum, and the FCV is open. The unit goes into Idling mode when there has been no pilot signal for the time set in DIR_Time, see Section 8.2.4 DIR_Time. FlexPAK Idling TimeToStandby 12:00m TimeToStandby: The amount of time until the unit goes into Standby mode. The default setting is 12 minutes. See Section 8.2.5 SSR_Time. 36