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Sideros ECO 4 HC-S Operation And Maintenance Manual

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OPERATION AND MAINTENANCE
MANUAL
CARTRIDGE DUST COLLECTOR
ECOLINE
SERIAL N. 368/19

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Summary of Contents for Sideros ECO 4 HC-S

  • Page 1 OPERATION AND MAINTENANCE MANUAL CARTRIDGE DUST COLLECTOR ECOLINE SERIAL N. 368/19...
  • Page 2 ECO FILTER – OPERATION AND MAINTENANCE MANUAL V 1.4 Page 2...
  • Page 3 Table of contents Introduction..........................4 Manufacturer’s identification data ..................4 1.1. 1.2. Data sheet ..........................5 1.3. Warranty ..........................7 Manual ............................8 2.1. Symbols ..........................9 Safety and accident prevention....................10 3.1. Safety signs and pictograms ....................11 3.2. Qualifications of skilled operators ..................
  • Page 4 1. Introduction We congratulate with you for choosing a Sideros Engineering filtering system. ECO model filters are used to abate and filter the fumes from the industrial thermal cutting of sheet metal, which includes oxygen, plasma and laser cutting. They are also used to collect the fumes from welding and the dusts generated by lapping and descaling metal objects.
  • Page 5 1.2. Data sheet Below are given the main characteristics of your machine, since the rating plate might become illegible with time and through use: Order confirmation N. 18/1243 Serial N. 368/19 Manufacture date 10/2019 Model ECO 4 HC/S Version for installation: INSIDE/OUTSIDE Motor fan power 5,5 kW...
  • Page 6 Characteristics of filtering elements TOP GRADE SELF-EXTINGUISHING – PP23 series Type of cartridge installed Filtering surface 21 m Filtering efficiency 99.999% with particle sizes up to 0.5 microns Dust emission after filtration < 2 mg/m Relative humidity of sucked air <...
  • Page 7 1.3. Warranty With reference to what detailed in this manual, SIDEROS ENGINEERING Company cannot be held responsible in the event of: ▪ use of the machine in violation of national safety and accident prevention rules ▪ wrong arrangement of the site and structures on which the machine will operate ▪...
  • Page 8 These directions are essential so that the system can be always run by responsible persons ensuring its correct operation, maintenance and repair. Should any technical problems arise, please contact Sideros Engineering at any moment.
  • Page 9 2.1. Symbols Some symbols are used in this manual to draw the reader’s attention and highlight some particularly important aspects of the text. The symbols used in the manual and their meanings are given in the table below. SYMBOL MEANING EXPLANATION, ADVICE, NOTES •...
  • Page 10 3. Safety and accident prevention Personnel exposure to dangers can be eliminated and/or significantly reduced only if the machine is used according to the instructions herein by authorised and specifically instructed personnel having sufficient training. Personnel must be informed about all potential dangers they will face while carrying out their tasks, as to the operation and correct use of the safety devices available on the machine.
  • Page 11 3.1. Safety signs and pictograms The manual contains a list of signs and pictograms which highlight or draw the attention on possible dangerous situations due to residual risks or actions which must be necessarily carried out according to the safety procedures described herein. The following is just a list of examples, some of which are present in the manual and/or on the machine.
  • Page 12 Indications of obligations: SIGN MEANING OBLIGATION TO REFER TO THE MANUAL Whenever this sign appears, preceding or inside an indication (instructions, records, maintenance, etc.), please refer to the SAFETY MANUAL. OBLIGATION TO WEAR GLOVES It is obligatory to use protective gloves. OBLIGATION TO WEAR A HELMET It is obligatory to use a protective helmet.
  • Page 13 Qualified personnel who are able to intervene under normal conditions for electric operations, adjustments, maintenance and repairs. MECHANICAL TECHNICIAN: A specialized technician, trained and/or charged by SIDEROS Engineering, who is authorized to perform complex and extraordinary mechanical operations. ELECTRONIC/ELECTRICAL TECHNICIAN: A specialized technician, trained and/or charged by SIDEROS Engineering, who is authorized to perform complex and extraordinary electric/electronic operations.
  • Page 14 Here are the main warnings which must be carefully observed to operate safely: HE OPERATOR MUST KNOW THE MACHINE CHARACTERISTICS AND BE ABLE TO USE IT CORRECTLY HE OPERATOR SHOULD NOT ALLOW ANYONE TO APPROACH DURING THE MACHINE OPERATION AND MUST PREVENT UNRELATED PERSONNEL FROM USING THE MACHINE HE OPERATOR MUST ALWAYS USE PERSONAL PROTECTIVE EQUIPMENT SHOES...
  • Page 15 RISKS DURING USE DANGER / RISK PROHIBITION / WARNING • It is forbidden to lift loads while people pass in Risk due to danger of being crushed while handling the relevant work area. suspended loads, if the operator or other personnel are •...
  • Page 16 The transport of the machine or parts or components of it, even when made on site, must be performed by qualified carriers to provide correct handling of the transported material. SIDEROS ENGINEERING company cannot be held responsible in the event of transport by the customer or carriers chosen by him.
  • Page 17 4.2. Handling HE LOAD MUST BE HORIZONTALLY ARRANGED TO GET MAXIMUM STABILITY THIS POSITION MUST BE MAINTAINED THROUGHOUT ALL HANDLING TRANSPORT AND STORAGE STEPS TO AVOID THE RISK OF OVERTURN HE LIFTING EQUIPMENT CAPACITY MUST MATCH THE LOAD TO BE HANDLED TAKING INTO ACCOUNT ADEQUATE MARGINS OF SAFETY EVER USE LIFTING DEVICES WHICH DO NOT COMPLY WITH SAFETY RULES Procedures are different according to the filter model.
  • Page 18 BSERVE THE PROPER SAFETY MEASURES AND CHECK IF THE LIFTING CHAINS ARE IN GOOD CONDITION SIDEROS ENGINEERING company cannot be held responsible for any damages to people or things due to the wrong handling of loads by unskilled personnel with improper lifting devices.
  • Page 19 The dust removed from the cartridge surfaces, along with the one precipitated by gravity, is collected in the basket below the dirty chamber for subsequent disposal. 5.1. Main components See drawings in Annex A for reference: Motor fan: it is sized according to the type of plant and specifically designed for the transport of dust mixed in air through a reverse blade impeller.
  • Page 20 Filtering cartridges: they are the ECO unit cores. They are made from treated cellulose, which is pleated and then inserted into a cylinder consisting of two sturdy metal sheet covers and two metal containment nets along their perimeter. The cartridges are self-extinguishing, that is of delayed combustion type, so as to prevent the development of flames in case of fire.
  • Page 21 Cyclic pulse generator: it is a programmable electronic control unit which is used to monitor the state of clogging of cartridges and to control the cleaning system. Equipped with a digital display, it gives the following data: ▪ cartridge cleaning pilot light ▪...
  • Page 22 Flow control valve: it works as a butterfly valve and is installed on the connection pipe between filter and machine. It is used to throttle the flow at the dirty chamber inlet during the cartridge running-in period. Flow-back preventing door (on request for ECO4 models): mounted on the lower part of the spark trap, it allows the dirty air entry and prevents its exit during the cleaning steps when the motor fan is off.
  • Page 23 An integral panel board and the cleaning system control panel are installed on the ECO unit. The panel board can be inspected only by Sideros maintainers. On the contrary, a simplified control board will be affixed on the building inner wall for the operator.
  • Page 24 Panel board Switchboard 6. Installation The Ecoline filter is normally supplied completely assembled. It must be installed in a proper place, making sure the floor is as even as possible and there is enough room for maintenance operations. A distance of 10 meter from cutting table to filtration unit is advised.
  • Page 25 Proceed as follows: Power on the control board and check its correct operation through the pilot light. Turn on the motor fan and immediately turn it off. Make sure the direction of rotation is the one indicated by the red arrow on the outer cap or the upper part of the clean chamber.
  • Page 26 ▪ Adjust the operating pressure through the handle in the lower part of the pressure regulator and make sure it is between 6 and 7 bar, which is the recommended range to obtain thorough cleaning during testing. 50N/lt of compressed air per pulse are needed when cleaning the cartridges in SFERA and “Spider” tanks and 230N/lt are needed in case of Full Immersion tanks (about 4/6 pulses per minute).
  • Page 27 Correct use Incorrect use ECO FILTER – OPERATION AND MAINTENANCE MANUAL V 1.4 Page 27...
  • Page 28 7. Working principle The Ecoline series filter is best used to filter fumes from thermal cutting, lapping and welding. Its use is very simple and requires minimum supervision by the operator who must only push the start and stop buttons on the switchboard and periodically empty the filtered particle collection containers.
  • Page 29 7.2. Work environment The Ecoline cartridge dust collector can be installed both inside the building, close to the cutting machine, and outside. In the former case, the building must be well lit, ventilated and provided with a robust and levelled floor. The machine is designed to work at ambient temperatures between -10 °C and +40 °C. ATEX 94/9/ HE MACHINE DESCRIBED HEREIN DOES...
  • Page 30 8. Maintenance We remind you that correct maintenance operations can minimise downtimes after a fault. A prompt repair prevents further deterioration of the machine. Use genuine spare parts as far as possible. LL OPERATIONS MUST BE PERFORMED BY AUTHORIZED PERSONNEL WHO HAVE READ AND UNDERSTOOD THE FOLLOWING MANUAL 8.1.
  • Page 31 Typical maintenance activities: ▪ Working on electrical equipment based on wiring diagrams ▪ Checking the electric components (electrical equipment contacts) for wear ▪ Repairing the electric assemblies upon replacement of certain parts with genuine spares. Required technical knowledge: ▪ Good knowledge of electrical equipment and installations ▪...
  • Page 32 IDEROS NGINEERING TECHNICAL SUPPORT Cleaning the dirty chamber 1. Perform a forced cleaning cycle with turned-off motor for twenty minutes (contact Sideros Engineering technical support) 2. Power down the switchboard through the On/Off selector switch (A) 3. Unscrew the filter front door locking elements 4.
  • Page 33 1. Halt the compressed air supply to the filter; 2. Perform a forced cleaning cycle with turned-off engine until the pneumatic system is free of compressed air (please contact Sideros Engineering’s technical support); 3. Power down the switchboard through the On/Off selector switch (A);...
  • Page 34 6. Unscrew the self-locking nut which locks the cartridge; 7. Place a plastic bag around the cartridge to minimize the discharge of dust from the vacuum cleaner; 8. Pull the cartridge towards the operator and remove it from its seat, then do the same with the other ones 9.
  • Page 35 11. Check the cartridge is perfectly perpendicular to the partition wall and the gasket is evenly compressed between cartridge and wall; 12. Close the doors and tighten the screws checking they are perfectly firm. In case of leaks between doors and main body, check the seals.
  • Page 36 REPLACEMENT PROCEDURE FOR THE ECO 24 FILTERING CARTRIDGES 1. First open the doors, remove the clamping bars and unscrew the self-locking nuts. 2. Discharge the used cartridges. 3. Remove the dust on the filtering dividing plate in order to guarantee the perfect bond between the gasket and the plate itself.
  • Page 37 NCE ENDED THE PREVIOUS PASSAGES CHECK THAT THE GASKETS STANDING ON THE FRONT SIDE OF THE CARTRIDGES ARE PERFECTLY ADHERENT TO THE SUPPORT FACES ’ IT IS IMPORTANT TO ENSURE THAT THERE AREN T ANY AIR LEAKAGE AREAS 6. Insert the M12 self-locking nut and the washer on each support (image 9). 7.
  • Page 38 8. Secure the clamping bars with the M12 nuts to the cartridge’s support structure (images 12 and 13). 9. Close the doors. Changing the motor fan 1. Power down the switchboard through the On/Off selector switch (A); 2. Halt the compressed air supply to the filter; 3.
  • Page 39 6. Unscrew the four eyebolts, the fixing screws and remove the roof of the filter. The roofs of the eco 4-6- 9-12 models weigh more than 25 kg so the handling by two people is mandatory; 7. Remove the roof’s support; 8.
  • Page 40 2. A manual cleaning cycle is recommended to relieve pressure, so that no pipes (B) must be disconnected with the system under pressure (contact Sideros Engineering technical support) 3. Cut the power supply to the machine by turning off the filter switchboard 4.
  • Page 41 8. Open the compressed air supply to the filter and switch on the filter switchboard 9. With the stopped machine (switched off motor fan), perform a manual cleaning cycle to check there is no air venting and the cleaning system has been correctly assembled (contact the Sideros Engineering technical support) 10.
  • Page 42 Maintenance of Spider cleaning system Part list for Spider cleaning system: Cod. “ELBOBPRECABL” For all dust collector models the cabled coil connectors are the same For all dust collector models the same solenoid valve is used, which is composed from: 1 Coil 1 Electromagnetic pilot 4 M6 x 20 screws with washers...
  • Page 43 A. Spider cleaning system B. Compressed air supply hose C. Wiring for actuation command D. Pneumatic fittings Procedure to disassemble a solenoid valve and its pneumatic drive DO NOT OPEN THE COMPRESSED AIR SUPPLY WHEN PIPES ARE DISCONNECTED DANGER OF INJURIES DUE TO PIPE RATTLING 1.
  • Page 44 10. Open the compressed air supply to the filter and switch on the filter switchboard 11. With the stopped machine (switched off motor fan), perform a manual cleaning cycle to check there is no air venting and the cleaning system has been correctly assembled (contact the Sideros Engineering technical support) ECO FILTER –...
  • Page 45 1. Check the door seal making sure there are no cracks, crushing and discontinuity which might compromise its perfect tightness 2. Replace the door and re-tighten the perimeter screws. Disassembly procedure of the whole cleaning system 1. Disconnect the air supply pipe (B) from the 90° bend fitting (D), as shown in Fig. 1 2.
  • Page 46 8. With the stopped machine (switched off motor fan), perform a manual cleaning cycle to check there is no air venting and the cleaning system has been correctly assembled (contact the Sideros Engineering technical support) 9. Check the door seal making sure there are no cracks, crushing and discontinuity which might compromise its perfect tightness 10.
  • Page 47 A. Full Immersion cleaning system B. Compressed air supply system pipes C. Drive electric cabling D. Double union for pneumatic connection E. Tee union to feed the cleaning system F. Pressure gauge Disassembly procedure of the whole cleaning system: this operation is recommended to perform checks and maintenance on Full Immersion system or for replacements in case of air venting not caused by the solenoid valve 1.
  • Page 48 8. Open the compressed air supply to the filter and switch on the filter switchboard 9. With the stopped machine (switched off motor fan), perform a manual cleaning cycle to check there is no air venting and the cleaning system has been correctly assembled (contact the Sideros Engineering technical support) 10.
  • Page 49 Fig. 3 Fig. 4 4. Take out all components as indicated in fig. 4 and make sure the gasket (I) is not cracked, the spring (H) is correctly seated and undamaged and the cover (G) is in good condition With a 14 mm socket wrench, unscrew the six screws securing the double diaphragm cover (L) 6.
  • Page 50 12. With the stopped machine (switched off motor fan), perform a manual cleaning cycle to check there is no air venting and the cleaning system has been correctly assembled (contact the Sideros Engineering technical support) 11. Check the door seal making sure there are no cracks, crushing and discontinuity which might compromise its perfect tightness 12.
  • Page 51 Below is a list of reasonably foreseeable malfunctions which might occur in the Ecoline filter. Don not start the machine in case of real or suspected fault. If in doubt, always contact the Sideros Engineering technical support. Always use genuine spare parts.
  • Page 52 Check the building’s compressed HE CLEANING Insufficient compressed air air network for correct operation SYSTEM DOES NOT Ask the Sideros technical support WORK Electric trouble in the control unit for the intervention of a technician Poorly tightened cartridges on reels...
  • Page 53 spacers on the floor for all packages without pallet protect all packages with barrier sacks and hygroscopic salts carpentry structural parts do not require special protections; on the contrary, machined parts (machined planes, wheels, pins, etc.) must be protected with antioxidant products (clear paints, grease, etc.) ▪...
  • Page 54 10. Spare parts See table on page 6 for spare part codes; refer to the drawings on annex A. Always call the Sideros Engineering technical support for technical advice and genuine spares. LWAYS USE GENUINE SPARE PARTS HE USE OF REPLACEMENT PARTS FROM THIRD...
  • Page 55 11. Accessories Upon customer’s request the following accessories can be provided for the Ecoline filter: ▪ Fast Clean motorised dust removal system: a gear motor drives a screw with a rotating motion which impels the dust from an access manifold, where it is collected, into a nylon tube containing the spiral. At the end of the path the material is delivered by a discharge manifold into a container ready for disposal.
  • Page 56 Rain guard cap Baffle / Stack outlet ▪ Functioning pressure range: On request, it is possible to install a pair of adjustable pressure switches on the regulator filter to define a working range based on the compressed air network pressure at the controller filter input.
  • Page 57 Annex A ECO FILTER – OPERATION AND MAINTENANCE MANUAL V 1.4 Page 57...
  • Page 58 ECO FILTER – OPERATION AND MAINTENANCE MANUAL V 1.4 Page 58...
  • Page 59 ECO FILTER – OPERATION AND MAINTENANCE MANUAL V 1.4 Page 59...
  • Page 60 ECO FILTER – OPERATION AND MAINTENANCE MANUAL V 1.4 Page 60...
  • Page 61 ECO FILTER – OPERATION AND MAINTENANCE MANUAL V 1.4 Page 61...
  • Page 62 ECO FILTER – OPERATION AND MAINTENANCE MANUAL V 1.4 Page 62...