Nederman FilterMax DX 3000, Instruction Manual

Page 1: ...CAPTURE AT SOURCE NO 148405 00 2001 02 01 This Instruction Manual refer only to FilterMax DX with the following particular part no INSTRUCTION MANUAL 0 1 ENGLISH ...

Page 2: ...m installation Operating description Product marking Starting the system Applications Monitoring system settings Monitoring system general descriptions Monitoring system fault indications Service instructions Trouble shooting schedule Spare parts Accessories Installation and service protocol 1 Installation and service protocol 2 Installation and service protocol 3 Installation and service protocol...

Page 3: ... 2 S 252 28 Helsingborg Sweden 2001 02 01 R Filtration Operating airflow Filterarea filter cartridge Filter material Environ temperature Process air dry temperature Material description Compressed air requirements Compressed air consumption Compressed air connection Voltage supply Protection class Relay voltage accessory Working pressure Pulse noise Weight Dimensions TECHNICAL DATA Basic filter 99...

Page 4: ...ed used and maintained according to this Instruction Manual in such a way that safety not will be neglected 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 0 1 H G F A C B E D J For FilterMax DX 6000 oand 9000 J Additional filter unit with relief panel J...

Page 5: ...bolts or equivalent fittings the concrete floor must be prepared accordingly The deflector must be designed and mounted in a way that makes it possible to be proof against an explosion 1 5 D D 45 PRE INSTALLATION A approximately height of FilterMax DX A A A Width according to the document Dust Application Description Length accordin to the document Dust Application Description View from above DANG...

Page 6: ... 2 MODULES OUTLET 1112 G 1395 1545 1200 120 2 0 50 1200 open angle 155 A B C D E F G H H 50 litres container In Outlet inner diameters mm 250 2590 3510 270 315 2615 3535 2700 3620 4540 1195 315 400 2685 3605 4525 3690 4610 1195 390 500 2810 3730 4650 4740 1195 440 6 ...

Page 7: ...are reversable and concequently they can be positioned for duct connection on the right or left side of the filter Use a schackle not a hook Fit the lifting loops around the strengthening tubes in the filter unit Use a lifting yoke as shown in the picture which allows the lifting loops to come near the outer edges of the unit 2 FilterMax DX is usually anchored to a concrete foun dation with expans...

Page 8: ...g screws 2 Loosen the nuts on the filter holders Remove the filter holders 4 Insert the new filter cartridges NB The mark on the back end cap should be put on the angled sheet metal plate just inside the filter hole 6 Connect the earth plate on 2 places as shown in the picture NB Toothed washers must be used to ensure the earth connection WARNING Risk of personal injury For FilterMax DX equipped w...

Page 9: ...upply pressure has to be 0 6 MPa 6 bar 87 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...

Page 10: ...uld be used The connection is done in the following way Thread the hole in the Control box Screw home the cable fitting Fit a lock nut on the cable fitting on the inside of the Control box Enclosed cable fittings 2 PG7 2 lock nuts in brass 2 PG11 2 lock nuts in brass 1 PG13 1 lock nut in brass Connect FILTERMAX to the mains and connect fan and other components and accessories according to the wiri...

Page 11: ... 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 WARNING Risk of personal injury Electric power connected The inputs or outputs should be activated wh...

Page 12: ...he same time while the main switch is switched on 5 Set the pressure at which the cleaning shall start normally 400 800 Pa EA OFF dF ON or NC or NO Explosion Fire alarm Push the button X Activated input JP1 7 Set OFF NC or NO with the 0 1 button 00 60 s Dust feeder Push the button X Activated output JP6 3 Direct controlled by contactor or other 24 V relay ON The dust feeder is in operation OFF The...

Page 13: ...ween all components according to the list above and GND 1 C Measure and check if contact between incoming duct system and the free coupled incoming net earth 2 Connect incoming duct system make sure that there is an earth connection between the duct system and FilterMax DX A Measure and check if contact between GND1 and extern net earth B Reconnect net earth to GND1 Connect outgoing duct system ma...

Page 14: ...r Down time damper NB Down time damper with spring return should be connected only to JP6 no 2 and no 8 2 3 GND1 Disconnect at earth control measuring Mains connection 100 120 230 V PE 50 60 Hz Magnetic door switch Pilot Box Connection of 2 or 3 pilot boxes see page 16 BASIC FUNCTIONS For fan start two alternatives are possible Alternative 1 Connection to bloc JP6 1 for direct control by contactor...

Page 15: ...2 01 01 01 LINE 1 NB LINE 1 LINE 3 LINE 2 Set LINE 1 LINE 2 or LINE 3 with the 0 1 button on the Control Box IMPORTANT The pilot boxes in line 2 and 3 must be configurated in the following way Remove the lower protection cover Set the switch on 2 or 3 depending on what line the pilot box belongs to NB Remove the clamp between 3 and 4 on the output contact before the cable from the pilot box above ...

Page 16: ... contact before the cable from the pilot box above is connected Total pressure Pa Air flow m3 h An adequate fan can be selected from the Nederman NCF EX range Please contact your Nederman representative for dimensioning the right fan capacity To start the NCF EX fans a Nederman Fan Starter PTC is recommended Calculated air pressure drop over the filter is approximately 1200 Pa A lockable safety sw...

Page 17: ...here can be explosive Use long radius bends Install plenty of cleaning access points in the ducting system before FilterMax DX If the dust is abrasive it may be necessary to use thick walled or rubber coted material in bends and other exposed areas 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 sid...

Page 18: ...e inlet The filter cartridge seen from above 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 The distribution generates a quiet and efficient cleaning pulse The filter controller controls the cleaning process Valve with cleaning pipe Explsion relief panel unloads the pressure at an explosion T...

Page 19: ... 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 NB Follow the start instructions in the Instruction Manual which comes with Nederman NCF EX fans 4 Adjust the fan for the proper system airflow that is desired by adjusting the regulating damper The air flow can be measured with a fixe...

Page 20: ...ltering dust with an MIT which is lower than the surface temperature of the pilot box 125 C MIT Minimum Ignition Temperature 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...

Page 21: ... that can t be stopped immediately when a fault accurs it is recommended that the A alarm switch is set to 1 ON and that a clearly visible alarm device is installed 1 ON The system does not stop when the A alarm is activated With exception for explsion fire alarm and motor protection fan The system always stops for these functions 1 OFF The system stops automatically when the A alarm is activated ...

Page 22: ...ee page 11 0 1 0 1 Blinks when the cleaning function operates Fixed light when the system operates 1 0 1 0 1 124 0 1 0 1 rE 0 1 0 1 Both point and 1 blinks when cleaning after operation is in progress 1 The system has stopped and the cleaning after operation is active If the 0 1 button is pressed once more the cleaning after operation is stopped immediately MONITORING SYSTEM GENERAL DESCRIPTIONS T...

Page 23: ...ry Check if any damper is not open enough Check the inlet for dirt Clean if necessary FilterMax DX has stopped due to low com pressed air pressure less than 0 4 MPa 4 bar FilterMax DX 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 ...

Page 24: ...ton If the filter is remotely started it will start directly when the 0 1 button is pressed The dust collector is full Empty the collector The door is open and FilterMax DX will not start The door has been opened during system operation Shut the door 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 defec...

Page 25: ...ned If the Minimum Ignition Energy MIE of the dust is less than 20 mJ the service personal must use shoes and other clothes specially designed to be used in explosion hazardous areas Tools used for service works on Filter Max DX then also must be approved for explosion hazardous areas SERVICE INSTRUCTIONS 25 1 Switch off the FilterMax DX 2 Put a pallet which can be operated by a lift truck under t...

Page 26: ... 6 per module that is 6 12 or 18 per cycle Check that the relief sheets on FilterMax DX not are damaged or blocked Remove dust collections from the lower part of the clean air room Remove dust collections on monitoring system and pilot box SERVICE AFTER 1000 OPERATION HOURS BUT AT LEAST ONCE EVERY 6TH MONTH REPLACING THE FILTER CARTRIDGES AT DAMAGE OR INSUFFICIENT FILTER FUNCTION BUT AT LEAST AFTE...

Page 27: ...sealed 10 Proceed in the same way with the remaining filter cartridges 11 Inspect the filter housing and look for damages dust layers etc Clean inside the filter housing A vacuum cleaner approved for use in explosive environments is recommended 12 Handle the new filter cartridges carefully to avoid damage 13 Insert the new filter cartridges NB The mark on the back end of the filter cartridge shoul...

Page 28: ...sed Are you trying to remote start FilterMax DX Contact your nearest Nederman representative for advice NO Correct the error indicated by the function LED s see page 23 24 YES Is the A alarm LED no 7 on TROUBLE SHOOTING SCHEDULE NO NO Is the display showing ERR another digit than 0 YES YES Contact your nearest Nederman representative for advice B FilterMax DX starts but stops after a while and the...

Page 29: ...r 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 of the unit and clean the preseparator NO YES Is the fan operating correctly Does the impeller rotate...

Page 30: ... valve sequence is 4 5 6 1 2 3 where 1 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 Does the display on the control box show ERR a digit G Leaking compressed air syste...

Page 31: ...s indicate the following A Part No and Control No see FilterMax DX identification plate B The spare part s name and number see Spare Parts List C Quantity of parts required Spare Parts List Name 1 Filter cartridge 6 pac 2 Circuit card 3 Control box complete incl electric components 4 Repair set for pulse valve 5 Pulse valve 6 Door switch 7 Cleaning pipe 8 Cover with display and cicuit card 0 1 0 1...

Page 32: ... Nederman product The damper closes the duct when FilterMax DX 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 DX inlet PRESSURE SWITCH Not a Nederman product Is used to indicate low airflow or high fall of pressure over the filter NB If the switch should be mounted i...

Page 33: ...nstallation control page 5 7 8 A Safe mounting foundation B Fixing bolts Traction forces C Wind Snow load D Weight FilterMax DX collected dust E Radiation heat F Convenience of service G Flame and pressure risk area H Approved lifting equipment J Conductible screw fittings K Inlet L Outlet M Dust collector N Dust feeder O 2 3 filter units P Filter cartridges Q Approved lifting platform R Duct fitt...

Page 34: ...protector C Safety switch EX proofed D After cleaning damper E Transformer F Pressure switch G Pilot box 1 2 or 3 H Fan J Extern START STOP K Pressure switch compressed air L Pressure switch high dP low airflow M Pressure switch simple dP control N Explosion Fire alarm O Fan Starter P Dust feeder Q Sum alarm R A alarm S Activating in outputs T Line connection page 15 Result Result Result Result Re...

Page 35: ...ming net earth M GND1 Net earth extern 7 Monitoring system settings page 20 21 A Cleaning during operation B Pause time setting C Cleaning after operation D A alarm function E Remote control 8 Service instructions page 25 27 A Emptying the dust collector B Water check filter regulator C Water check pressure tank D Magnet valves function check E Relief panels F Cleaning access covers cleaning G Rem...

Page 36: ...36 INSTALLATION AND SERVICE PROTOCOL 4 Point no Date Note ...

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