THERMACUT 880200-40 Operating Instructions Manual

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880200-40

Filter system

Operating instructions EX-0-922-001

Edition 1, 2024-09-19

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Page 1 880200-40 Filter system Operating instructions EX-0-922-001 Edition 1, 2024-09-19...
Page 2: Table Of Contents
880200-40 Table of contents 1 Identification .......................... Signs and symbols used ............................Classification of the warnings ..........................Product label ................................Declaration of Conformity............................Nameplate ................................2 Safety............................. Designated use................................. Obligations of the operator ............................ Warnings and Information Signs..........................10 Safety Instructions ..............................
Page 3 880200-40 10 Maintenance and cleaning ...................... 30 10.1 Maintenance and Cleaning Intervals ........................31 10.2 Emptying the Dust Collecting Container ........................ 32 10.3 Draining Condensate .............................. 33 10.4 Carrying Out Functional Test ..........................34 10.5 Carrying Out Electrical Check..........................34 10.6 Replacing Filter Cartridges............................
Page 4: Identification
1 Identification 880200-40 Identification The device is used for extracting welding, cutting, and grinding fumes. Signs and symbols used In these operating instructions, the following signs and symbols are used: General instructions. Steps to be carried out in succession. Lists.
Page 5: Classification Of The Warnings
880200-40 1 Identification Classification of the warnings The warning notices used are divided into four different levels and are printed in front of potentially dangerous work steps. Depending on the type of danger, the following signal words are used: DANGER Describes an imminent danger.
Page 6: Declaration Of Conformity
1 Identification 880200-40 Declaration of Conformity EN - 6 EX-0-922-001 • Edition 1...
Page 7 880200-40 1 Identification EN - 7 EX-0-922-001 • Edition 1...
Page 8: Nameplate
1 Identification 880200-40 Nameplate The device is labeled by means of a nameplate. ► For inquiries, please have at hand the device type, device number, and year of construction as indicated on the nameplate. Figure 1 Nameplate EN - 8 EX-0-922-001 • Edition 1...
Page 9: Safety
Any other use is considered non-intended. Unauthorized conversion work or modifications to increase performance are not permissible. ► Only operate the unit with original THERMACUT spare parts. ► Do not exceed the maximum load data given in the documents. Excess loads will lead to irreparable damage.
Page 10: Warnings And Information Signs
2 Safety 880200-40 Warnings and Information Signs The following warning, notice and mandatory signs can be found on the product. These markings must always be legible. They may not be covered, obscured, painted over, or removed. ► Read and follow the operating manual.
Page 11: Safety Instructions
880200-40 2 Safety Safety Instructions 2.4.1 Basic safety instructions The device has been developed and manufactured in accordance with the latest technology and recognized safety standards and directives. Due to the device design, unavoidable technical residual risks exist to the user, third parties, devices, and other material property. The manufacturer will accept no liability for damage caused by non-observance of the documentation.
Page 12: Safety Instructions For Welding, Cutting, And Grinding
2 Safety 880200-40 2.4.4 Safety instructions for welding, cutting, and grinding ► Arc welding, thermal cutting, and grinding can damage eyes, skin, and hearing. Note that further hazards can occur in connection with other components. For this reason, always wear the mandatory protective clothing in accordance with local laws and directives.
Page 13: Scope Of Delivery
3 Scope of Delivery Scope of Delivery The following components are included in the scope of delivery: – 1x filter system 880200-40 – 1x operating manual ► Order the equipment parts and wear parts separately. ► The order data for the equipment parts and wear parts can be found in the current order documents.
Page 14: Product Description
4 Product Description 880200-40 Product Description Structure and Function Figure 2 Structure and function Air inlet Dust collecting container 2x ventilator Air exhaust louver Compressed air unit 2x filter cartridges Compressed air tank Areas of application for the device are automated welding, grinding or thermal cutting up to a max.
Page 15: Operator Controls And Connections
880200-40 4 Product Description Operator Controls and Connections Figure 3 Operator controls and connections Compressed air connection Main switch Mains connecting cable Connecting socket for remote On/Off switch Manual cleaning switch <I/O> switch Control display Electric unit <I/O> switch Extraction is activated when the <I/O> switch is set to <I>.
Page 16 4 Product Description 880200-40 Figure 4 Control display Slot with software flash drive Arrow buttons <OK> button to enter/confirm <ESC> button to cancel/return to higher- level menus Display The device is controlled by a PLC. The buttons on the device's electric unit control display are used for control.
Page 17: Technical Data
880200-40 5 Technical data Technical data Ambient Conditions Temperature of the ambient air -10 °C to +40 °C Relative air humidity Up to 80% non-condensing Table 1 Ambient conditions for transport and storage Temperature of the ambient air +10 °C to +40 °C Relative air humidity Up to 70% non-condensing Max.
Page 18: Transport And Setup
6 Transport and Setup 880200-40 880200-40 Compressed air 120 l/min consumption Weight Approx. 490 kg Dimensions (LxWxH) 1420 mm x 800 mm x 2445 mm Table 3 Product data Transport and Setup WARNING Risk of injury due to improper transport and setup Improper transport and setup can lead to the unit tilting or falling.
Page 19: Installation With A Forklift
880200-40 6 Transport and Setup Installation with a Forklift Drive under the device with a forklift on the long or short side. Transport to a suitable installation site but do not set down yet. Loosen all screws on the transport pallet.
Page 20: Installation With Lifting Gear
6 Transport and Setup 880200-40 Installation with Lifting Gear Loosen the tension locks of the upper cover plate on both sides. Two people should work together to carefully remove the upper cover plate. Hook the lifting gear into the transport lugs.
Page 21 880200-40 6 Transport and Setup Mark the drill holes (4x) on the floor and use a percussion drill to drill the holes. Insert the hammerset anchors into the drilled holes. Screw the feet firmly into the floor of the room where the device is to be installed using the hammerset anchors.
Page 22: Putting Into Operation
7 Putting Into Operation 880200-40 Putting Into Operation Mounting the Piping to the Air Inlet The customer's piping can be mounted on the right- or left-hand side of the device at the air inlet. The side without a connection must always be closed with the cover plate to ensure optimum extraction.
Page 23: Fitting Compressed Air Hose
880200-40 7 Putting Into Operation Fitting Compressed Air Hose Mount the compressed air hose with a hose clamp on the compressed air connection and connect to the compressed air supply. Use a compressed air hose with an inside diameter of a min. of 9 mm and a max.
Page 24: Connecting The Remote On/Off Switch (Optional)
7 Putting Into Operation 880200-40 Connecting the Remote On/Off Switch (optional) WARNING Electric shock due to damaged or improperly installed cable The use of damaged or improperly installed cables may result in a potentially fatal electric shock. ► Check all live cables and connections for proper installation and damage.
Page 25: Carrying Out A Functional Test
880200-40 7 Putting Into Operation Carrying out a Functional Test Switch on the customer's compressed air supply. Check that the pressure on the compressed air reducer is between 5 bar and 6 bar. If the pressure is below 5 bar, the device will signal a compressed air fault. If the pressure is above 7 bar, the pressure relief valve in the clean room area of the device opens.
Page 26: Operation
8 Operation 880200-40 Operation WARNING Health risk due to inhalation of harmful welding, grinding, and cutting fumes Welding, grinding and thermal cutting processes produce fumes containing harmful dust particles that can settle on surfaces and be released into the ambient air. The respiratory system can be damaged if inhaled.
Page 27: Starting And Stopping Extraction
880200-40 8 Operation Starting and Stopping Extraction To start extraction, set the <I/O> switch to <I>. To stop extraction, set the <I/O> switch to <O>. Alternatively, start extraction using the optional remote On/Off switch. After extraction has been stopped, the filters are dedusted twice automatically.
Page 28: Indications On The Control Display
8 Operation 880200-40 Indications on the Control Display Display for cleaning process During operation, dust is extracted into the filter cartridge and adheres there. This leads to a pressure difference between the clean air side and the dirty air side. When the pressure difference reaches the preset value, the filter initiates the cleaning process and automatically cleans both cartridges one after the other.
Page 29: Putting Out Of Operation
880200-40 9 Putting Out of Operation Putting Out of Operation Disconnect the device from the compressed air supply. Open the rotary knob on the compressed air reducer (relax). Set the main switch to <O>. Disconnect the device from the power supply.
Page 30: Maintenance And Cleaning
10 Maintenance and cleaning 880200-40 Maintenance and cleaning Regular maintenance and cleaning are prerequisites for a long service life and perfect function. The regular removal of dust can extend the service life of the filter cartridges. The maintenance interval is determined by the working environment and operating time of the units. If the unit is operated for longer than 8 hours per day, the maintenance interval should be adapted according...
Page 31: Maintenance And Cleaning Intervals
Annually or every ► Have a functional test on the device carried out by a 1600 operating hours qualified expert or THERMACUT Service.ð 10.4 Carrying Out Functional Test (Page 34) If the indicator light of the ► Check both filter cartridges and replace if necessary.ð 10.6 <Manual cleaning>...
Page 32: Emptying The Dust Collecting Container
10 Maintenance and cleaning 880200-40 10.2 Emptying the Dust Collecting Container WARNING Health risk through inhalation of harmful dust If the dust collecting container is not emptied properly, harmful dust and dirt particles can get into the surrounding air. They can damage the respiratory system if inhaled.
Page 33: Draining Condensate
880200-40 10 Maintenance and cleaning Replace the grill. Insert the dust collecting container. Unlock the compressed air valve lever lock and move the lever up to lock the compressed air lock for the dust collecting container. Close the door. 10.3 Draining Condensate Open the door.
Page 34: Carrying Out Functional Test
10.4 Carrying Out Functional Test The functional test may only be carried out by a qualified expert or THERMACUT Service. Carry out a visual inspection of the device and all cables and connection lines. Carry out a visual inspection of the pneumatic lines.
Page 35: Replacing Filter Cartridges
880200-40 10 Maintenance and cleaning 10.6 Replacing Filter Cartridges Use a ladder or other suitable climbing aid to replace the filter cartridges. Always replace both filter cartridges. NOTE Damage to the rotation nozzle through faulty removal or insertion A rotation nozzle can become damaged through faulty removal and insertion.
Page 36 10 Maintenance and cleaning 880200-40 Remove the solenoid valve. Loosen the screw clamp on the air hose using a size 10 wrench. Remove the air hose. Loosen four screws using a size 13 wrench. Carefully detach the differential pressure monitor hose from the silicone or alternatively, cut it.
Page 37 880200-40 10 Maintenance and cleaning Remove the rotary nozzle from the filter cartridge. Carefully remove the filter cartridge. Seal the filter cartridge dust-tight in the dust collecting bag (cable pull/cable tie). Dispose of the dust collecting bag with the filter cartridge in accordance with local laws and directives.
Page 38 10 Maintenance and cleaning 880200-40 Open the plastic cap. To check that the cartridge filter has a correct centric fit, look through the opening into the cartridge filter. Close the plastic cap. Tighten all screws. Check the air hose for damage and replace if necessary.
Page 39: Faults And Their Correction
► Remove dust deposits in the surrounding area immediately using an industrial vacuum cleaner of dust class H or a damp cloth. ► Consult the documentation of all components used. ► Contact your retailer or THERMACUT in the event of questions or problems. Fault Cause Correction Indicator light of the <Manual...
Page 40 ► Increase the volume flow (approx. 4 m No flow of air Motor has stopped. ► Restart the motor. ► Contact THERMACUT Service if necessary. Device incorrectly connected ► Check the clockwise rotary to the power supply. field. ð 7.5 Establishing the Power Supply (Page 24)
Page 41: Check Position Of The Dust Collecting Container
Differential pressure The preset differential pressure has been reached. Change filter cartridges. Contact THERMACUT Service if necessary. Check the compressed air supply Required pressure in compressed air tank is not reached. Filter cartridges cannot be cleaned. If the compressed air supply is too low, the device is automatically switched off.
Page 42 11 Faults and their Correction 880200-40 THERMACUT Contact the service team. Contact the service team The device must be checked by qualified personnel. THERMACUT Contact the service team. EN - 42 EX-0-922-001 • Edition 1...
Page 43: Disassembly
880200-40 12 Disassembly Disassembly CAUTION Risk of injury due to unexpected start If power is supplied during maintenance, cleaning or disassembly, rotating parts can start running unexpectedly and lead to injuries from cuts. ► Switch off the device. ► Disconnect all electrical connections.
Page 44: Disposal
► Observe the local laws and regulations on disposal provisions in the safety data sheets of the consumables manufacturer. 13.5 Disposing of packaging THERMACUT has reduced the transport packaging to a minimum. The ability to recycle packaging materials was always considered during their selection. ► Heed local laws and directives on disposal. EN - 44...
Page 45: Spares And Wear Parts
880200-40 14 Spares and Wear Parts Spares and Wear Parts Item Item designation Item number HERR air valve 2/2, 24 V AC/50 Hz EX-0-715-001 Membrane EX-0-715-025 T-piece connector 1" EX-0-715-004 Angle 90° IG + AG galv. G1" EX-0-715-003 Hose clamp 31–34, width 20 mm EX-0-715-005 Pressure hose NW25/4.3 mm...
Page 46 14 Spares and Wear Parts 880200-40 Item Item designation Item number HERR filter cartridge, 20 m , ePTFE, L=1200 mm EX-0-711-001 Compressed air unit 0–12 bar EX-0-715-008 LOGO! logic module 24RC A8 EX-0-715-014 Pressure switch 1/4" with protective cap 1–10 EX-0-715-019 No illustration Transformer/40 VA/50–60 Hz, Input: 115 V/230 V/ EX-0-715-020 380 V, Output: 24 V (40 VA)/220 V (23 VA)
Page 47: Circuit Diagram
880200-40 15 Circuit diagram Circuit diagram EN - 47 EX-0-922-001 • Edition 1...
Page 48 15 Circuit diagram 880200-40 EN - 48 EX-0-922-001 • Edition 1...
Page 49 880200-40 15 Circuit diagram EN - 49 EX-0-922-001 • Edition 1...
Page 50 15 Circuit diagram 880200-40 EN - 50 EX-0-922-001 • Edition 1...
Page 51: Addresses And Contacts
Fax: +49 (0)2736 29 49 11-77 Email: thermacut@gs.t-com.hr Email: info@thermacut.de www.thermacut.hr www.thermacut.de POLAND FRANCE THERMACUT-POLAND SP. Z O.O. THERMACUT FRANCE ul. Stawowa 20 6 Rue des Frères Lumière 43-400 Cieszyn 67201 Eckbolsheim Tel.: +48 33 852 13 34 Tel.: +33 3 88 76 58 75 Email: thermacut@thermacut.pl...
Page 52 Tel: +36 (23) 521 430 Fax: 0045-43622324 Email: aruhaz@cooptim.hu Email: ac@binzel.se, www.thermacut.hu ket@binzel.se www.thermacut.net SLOVAKIA THERMACUT SLOVAKIA, s.r.o. Priemyselná ulica 1239 931 01 Šamorín Tel.: +421 31 591 0121 +421 903 644 954 Email: obchod@thermacut.sk www.thermacut.sk EN - 52 EX-0-922-001 • Edition 1...
Page 53 Email: ezio.minh@mnt.com.vn Email: info@thermacut.com.kz www.thermacut.net www.thermacut.kz SOUTH KOREA JAPAN Abicor Binzel Korea Ltd. Thermacut Japan Ltd. #A-101, 263, Gaejwa-ro 3F Shin-Osaka Hankyu Building Guemjeong-gu 1-1-1, Miyahara, Yodogawa-ku, Osaka Busan 532-0003 Japan Tel.: 0082 (31) 732 6065 / 6066 / 6067...
Page 54 16 Addresses and contacts 880200-40 EX-0-922-001 • Edition 1...
Page 55 880200-40 16 Addresses and contacts EX-0-922-001 • Edition 1...