DIVERSITECH FRED JR, FRED-JR-T, FRED SR, FRED SR2, FRED SR2 C Operation & Maintenance Manual

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Page 1

DIVERSITECH

Operation & Maintenance Manual

FRED JR

Visit our Website for more information on this product

2500 Alphonse Gariepy, Montreal, Quebec H8T 3M2

Tel: 1.800.361.3733 | Fax: 1.514.631.9480 | [email protected]

READ AND SAVE THESE INSTRUCTIONS

www.diversitech.ca

OMM-FJR-105 [E N]

Page 2

Table of Contents

SECTION 1 – SAFETY PRECAUTIONS OF FUME & DUST EXTRACTION/COLLECTION ................................................................3

1.1 Symbols .....................................................................................................................................................3

1.2 User Responsibility .......................................................................................................................................3

1.3 Fume Extraction Hazards ........................................................................................................................3

1.4 Dust Collection Hazards .........................................................................................................................3

1.5 Safety Stickers .......................................................................................................................................4

SECTION 2 – SPECIFICATIONS ...................................................................................................................................................4

2.1 Diagram & Description ..............................................................................................................................................4

2.2 Product Specifications ..............................................................................................................................................5

2.3 Dimension ...............................................................................................................................................................5

2.4 Filter Specifications ..................................................................................................................................................5

SECTION 3 – SETUP / INSTALLATION ...................................................................................................................................6

3.1 To Setup or Install Safely ..........................................................................................................................................6

3.2 Un-Packaging ...........................................................................................................................................................6

3.3 Tools Required ..........................................................................................................................................................6

3.4 Mounting Options ....................................................................................................................................................6

3.5 Electrical Options .....................................................................................................................................................6

SECTION 4 – OPERATION ...................................................................................................................................................7

4.1 To Operate Safely ....................................................................................................................................................7

4.2 Controls .................................................................................................................................................................7

4.3 Pre-Use Checklist ....................................................................................................................................................7

4.4 Principles of Operation ..........................................................................................................................................8

4.5 Failure Event ...........................................................................................................................................................8

SECTION 5 – MAINTENANCE & TROUBLESHOOTING ...........................................................................................................9

5.1 To Maintain this Product Safely .............................................................................................................................9

5.2 Tools Required ......................................................................................................................................................9

5.3 Routine Maintenance Schedule .............................................................................................................................10

5.4 Servicing Filter ......................................................................................................................................................10

5.5 Troubleshooting Procedure ....................................................................................................................................11

SECTION 6 – DECOMMISSIONING .............................................................................................................................................12

6.1 To Decommission this Product Safely .....................................................................................................................12

6.2 Tools Required ......................................................................................................................................................12

6.3 Comformity with Recycling Regulations ................................................................................................................12

APPENDIX 1A – ELECTRICAL DIAGRAM MANUAL [120 VAC] Single Phase Power ....................................................................13

APPENDIX 1B – ELECTRICAL DIAGRAM MANUAL [230/460/575v] 3-Phase Power ................................................................14

APPENDIX 2 – MAINTENANCE RECORD ..............................................................................................................................15

APPENDIX 3 – ARM-TO-BLOWER DIRECT INSTALLATION ................................................................................................16,17

APPENDIX 4 – FILTER INSTALLATION .......................................................................................................................18,19,20

APPENDIX 5 – PARTS LIST .................................................................................................................................................21

APPENDIX 6 – SAMPLES SAFETY STICKERS .........................................................................................................................22

NOTES...........................................................................................................................................................................23

Limited Equipment Warranty ................................................................................................................................Back Cover

Freight Claims .....................................................................................................................................................Back Cover

Return Material Policy ..........................................................................................................................................Back Cover

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SECTION 1 - SAFETY PRECAUTIONS OF FUME & DUST EXTRACTION/COLLECTION

1.1 Symbols

This manual uses several symbols to highlight specific hazards. Be familiar with these symbols and when you see them in this manual, read adjoining warning text to avoid the hazard.

READ

BEFORE

USE

NOT

USE

This manual contains specific cautionary statements related to worker safety. To protect yourself and others, read this manual thoroughly and follow as directed

before use. Not all hazards of fume & dust control are listed in this manual, and no hazards related to welding, cutting, grinding, painting, deburring or other applications are listed. Consult a qualified safety professional.

Do not use this equipment:

• To extract smoked or fumes above 180°F/82°C.

• To extract combustibles dust, liquid vapors, or aggressive fumes such as acids.

• If the power cord has been damaged or ground (third prong) removed.

• Without a filter.

WARNING!

DANGER!

ELECTRIC

SHOCK

MOVING

PARTS

HOT

PARTS

1.2 Users Responsability

• Improper use can be hazardous.

• All users must carefully read and understand this instruction manual prior to use

• No objects, such as tools, should be placed on the machine.

• When moving machine, care should be taken to ensure the users feet remain clear of the wheels.

• Machine weights 474 lbs without a capture arm, proper care should be taken when moving.

• Motor should not contact any objects, and all motor repairs should be performed while the power switch is off and the power source is disconnected. Operator should not touch motor during use.

• Blower assembly should not contact any objects, and all blower repairs should be performed while the power switch is off and the power source is disconnected. Operator should not touch blower during use.

• For maintenance of any and all components, power switch must be off and the power source disconnected

• It is your responsibility to follow all applicable ANSI, OSHA, UL, CSA, National & Local Fire Codes, and other regulatory guidelines covering the safe use of equipment that extracts fumes, collects dusts, and exhausts filtered air either indoors or outdoors.

• Before use, inspect the unit for damage and verify it is working properly.

• Only qualified persons should install, operate, maintain, or repair this unit.

• Do not modify or repair the unit with parts or accessories not supplied by the manufacturer.

• Consult filter manufacturer’s instructions for filter use and reuse, including instructions for cleaning.

1.3 Fume Extraction Hazards

• Breathing smoke, fumes, or dusts produced in applications such as welding, cutting, grinding, painting, deburring are hazardous to user’s health. Proper ventilation or use of well maintained fume extraction and/or dust collection equipment helps the user avoid these hazards.

• Breathable contaminants may not be visible or have an odor.

• Stop operation and leave the area immediately if 1) breathing becomes difficult, 2) experience dizziness, impaired vision, 4) or eye/nose/mouth irritation.

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1.4 Dust Collection Hazards

• Dusts from many metalwork, welding, cutting, grinding, painting, or deburring applications can be combustible.

• Do not use or install equipment where any potential for combustible fumes or dusts are present, until a qualified person has indicated it is safe to do so.

• Never use or install equipment where the potential for combustible fumes or dusts are present without a fire/explosion protection system.

• If you are unsure if the product you purchased is correct for your application, call DiversiTech at 1-800-361-3733.

1.5 Safety Stickers

• This machine is equipped with safety stickers to remind operators of the inherent dangers during use and maintenance.

• The stickers are only reminders, and all safety precautions contained in this manual must be well understood and adhered to by all users.

• See APPENDIX 6: Sample Safety Stickers for example of stickers applied to machine.

SECTION 2 - SPECIFICATIONS

2.1 Diagram & Description

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2.2 Product Specifications

Nominal

Model

FRED-JR with externally articulated manual capture arm

FRED-JR

FRED-JR with Fume Tracker™ hands-free capture arm

FRED -JR -T

Airflow

(CFM)

120 0 1.5

180 0 3.0

120 0 1.5

180 0 3.0

Motor

(H.P)

2.4 Dimensions

Arm

Length

Model

FRED-JR with externally articulated manual capture arm

FRED-JR

FRED-JR with Fume Tracker™ hands-free capture arm

FRED -JR -T

(ft.)

10 6 32.5 115 33 13 60 34 18. 5

13 6 32.5 128 33 13 60 60 18.5

10 6 32.5 115 33 13 60 34 18. 5

13 6 32.5 128 33 13 75 34 18.5

Arm

Diameter

(ft.)

Phase

(hz)

1P/60Hz

3P/60Hz

1P/60Hz

3P/60Hz

Width

[a]

@120 V (amps)

13. 2

---

13. 2

---

Height

[C]

Power Cord

@230V (amps)

--- --- ---

7.1

---

7.1 3.7

Length

@440V (amps)

3.7

--- ---

Footprint (in.)

[b] [d] [e] [f] [g]

@575V (amps)

3.2

Length

(ft.)

15 10/13

---

15 10/13

---

Arm

Length

(ft.)

10/13

2.3 Filter Specifications

Description Stage

Nano-Fiber Filter Primary S-JR-26NF 320 MER V 15 Yes

Paper-Pleated Filter Primary S-JR-0005 105 ME R V 11 Yes

HEPA Filter After-Filter S-JR -10 09 --- M E RV 17 No

Part #

Filter Area (sq. ft.)

For information on inspecting and cleaning filter, or purchasing replacement filters, contact DiversiTech at 1-800-361-3733.

Filter

Efficiency Reusable

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SECTION 3 - PRE-INSTALLATION

3.1 To Setup or Install Safely

• Do not place unit near flammables or combustible surface.

• Refer to SECTION 2: Specifications, to know the electrical requirements of the unit you are

3.2 Un-Packaging

1. Immediately upon receiving the unit, carefully examine the carton for damage during transit.

2. Use lift forks or truck to move

3. Remove packing material.

4. Avoid tipping or inverting during handling.

5. The item serial number, model, and electrical ratings are listed on the nameplate. Record this information in the Maintenance Record provided in APPENDIX 2: Maintenance Record, or your own preventative maintenance system.

3.3 Tools Required

1. 7/16 Socket or Wrench

2. 9/16 Socket or Wrench

3. Torque Wrench

installing and ensure adequate input power that is properly sized, rated, and protected.

• This unit must be grounded for safe operation.

The tools above are required for unit assembly.

3.4 Mounting Options

• Arm-To-Blower Direct Installation: Follow guidelines in APPENDIX 3: Arm-to-Blower Direct Installation.

3.5 Electrical Options

• Single-Phase Unit: See APPENDIX 1A: Electrical Diagram [120 VAC] Single-Phase Power for wiring instructions. Have a certified electrician install unit according to local regulations.

• 3-Phase Unit: See APPENDIX 1B: Electrical Diagram [230/460/575 VAC] 3-Phase Power for wiring instructions. Have a certified electrician install unit according to local regulations.

Page 7

SECTION 4 - OPERATION

4.1 To Operate Safely

• Read and understand SECTION 1: Safety Precautions and SECTION 4: Operation before use

• Read and understand all Material Safety Data Sheets and Manufacturer’s instructions of all process materials, consumables, and equipment used in conjunction with this equipment.

• Keep away from all mechanical moving parts including motor, gears, and other pinch points.

• Do not use product without first confirming if a Spark Arrestor is required and installed for the type of dust, or fumes you are extracting and/or collection. If you are unsure, call a

DiversiTech representative at 1-800-361-3733.

4.2 Controls

• The machine controls are basic, and consist solely of a power switch with ON and OFF positions.

• If the machine is equipped with a Minihelic differential pressure gauge, the Minihelic should read between .8 and 4.2 inches W.C. during normal operation.

• For a reading of more than 4 inches W.C, consult SECTION 5: Maintenance

and Troubleshooting as filter servicing may be required

4.3 Pre-Use Checklist

• Read and understand SECTION 1: Safety Precautions and ensure SECTION 3: Pre-Installation has been followed.

• Before plugging unit in to an input power source, look at the manufacturer’s label located on the exterior of the unit and ensure the source is correctly sized in terms of Voltage and Amperes.

• Prior to use in your application, turn the unit ON, and perform a function test. To do so:

2. Turn switch to ON position.

3. LOOK: Is the unit level, stable, and that nothing is obstructing the extraction path.

4. LISTEN: Does the motor and suction sound smooth and within expected volumes.

5. FEEL: Place your hand on top of the unit and sense for unexpected vibration. Place you hand in front of the intake hood/surface and sense for expected level(s) of suction.

• Inform all potential users of this equipment where they may find and review this manual.

1. LOOK: Have the front and back doors been closed properly.

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4.4 Principles of Operation

This product is designed to capture and clean smoke and dust from medium & heavy duty welding, soldering, and grinding applications. When operating, air is drawn in to the nozzle, passes through the 7” diameter hose, then through the air cleaner’s filtration system, and is exhausted through the rear discharge.

This product consists of four basic components:

1. Capture Arm(s)

2. A blower

3. Cartridge Filter

4. Motor & Electrical assemblies

• The operator is to positon the machine within operating distance, and activate the caster wheel brakes.

• The operator can then position the capture arm close enough to the worksite to capture all dust and fumes that will be produced.

• Ensuring that all safety procedures have been followed, the operator can turn on the machine and begin working.

• When not in use, the machine should be turned off.

4.5 Failure Event

If, for some reason, during operation there is an accident, a blockage occurs, the Minihelic displays abnormal pressure differences, or the machine begins to act abnormally, the operator should immediately shut off the machine. This is considered a machine failure and the following steps should be taken:

This product consists of four basic components:

1. Turn the power switch to the OFF position.

3. Seek medical attention if an accident occurred.

4. Follow the guidelines in SECTION 5: Maintenance and Troubleshooting.

Remember, under no circumstance should the machine be turned back on while performing maintenance.

Page 9

SECTION 5 - MAINTENANCE & TROUBLESHOOTING

5.1 To Maintain this Product Safely

• Read and understand SECTION 1: Safety Precautions and SECTION 4: Operation before maintenance.

• Do not breathe the dust collected from product while changing/cleaning filters or performing maintenance on this product.

• Disconnect power before performing any maintenance on unit, including filter inspection. The input power to this unit is high voltage, and touching any live electrical parts can cause fatal shocks or severe burns. Do not touch live electrical parts.

5.2 Tools Required

EYE

PROTECTION

• Keep away from all mechanical moving parts including motor, gears, and other pinch points while operating.

• Operating this unit causes some parts to heat to a point that will burn bare hands. Before maintenance allow parts to cool, or use proper tools and personal protection equipment during maintenance.

RESPIRATOR GLOVES

WASTE

CONTAINER

REPLACEMENT

FILTER

(if required)

Page 10

5.3 Routine Maintenance Schedule

The manufacturer recommends the following routine maintenance based on light-duty use in normal operating conditions. Service more frequently if the unit is used in severe conditions.

Frecuency Manual Reference

Pre-Use

• Perform pre-use inspection to ensure operating correctly. 4.3

Clean Filter

1. Place filter in garbage bag with the open end facing down

2. Blow off the filter cartridge using dry shop air

3. Material will collect in the bag for easy disposal

As Required – Replace Filter

1. Replace Filter

Every (12) months Inspect Basic Components

1. Clean unreadable labels and exterior surfaces

2. Capture Arm: Check for tears in flex hoses and fitting of hose clamps

3. Cabinet: Look for loose wiring.

5.4 Servicing Filter

1. Review Section 5.1: To Maintain this product Safely

2. Consult APPENDIX 4: Filter Installation.

3. Turn off power and disconnect input power cord.

4. Detach Rear Panel by first unclasping twist-lock latches located on rear of the main body.

5. Push the Retention Rod Handle to the forward most position

6. Slide and lock the Locking Bolt in the left most position

7. Pull the Retention Rod Handle to lower the filter

8. Remove filter by gently sliding out of enclosure so as to minimize agitating dirt and dust, and place it in a bag/container.

9. Clean filter:

• Use clean/dry air only at a pressure not more than 80 psi at 12” from media.

• Direct the compressed air through the filter from the clean side, running the nozzle up and down the filter pleats.

• Do not bring either nozzle in contact with the filter media as damage is likely to occur.

10. Inspect filter for any damage and replace if necessary.

11. Clean cabinet interior of dirt and debris.

12. Reassemble:

• Pull Retention Rod Handle to lowest position to allow space for filter.

• Slide in clean filter.

• Push Retention Rod Handle to forward most position.

• Slide and lock the Locking Bolt in the right most position, ensuring it locks the Retention Rod Handle.

Page 11

5.5 Troubleshooting Procedure

Turn Unit

Check Leads at

Input Power

Source

Motor

Operating

NO NO

Check Leads at

Unit

NO INTERMITTENTLY

Motor

Operating

YES

Air Flow

Restricted

YES

Check/clean Hood inlet &

Capture tubes

Air Flow

Restricted

YES

Call for Service

1(800)361-3733

[email protected]

Replace

Filter

Call for Service

1(800)361-3733

[email protected]

Unit Operates

Properly

Air Flow

YES

Restricted

YES

Call for Service

1(800)361-3733

[email protected]

Page 12

SECTION 6 - DECOMMISSIONING

6.1 To Decommission this Product Safely

• Read and understand SECTION 1: Safety Precautions and SECTION 4: Operation before maintenance.

• Do not breathe the dust collected from product while changing/cleaning filters or performing maintenance on this product.

6.2 Tools Required

1. 7/16 Socket or Wrench

2. 9/16 Socket or Wrench

The tools above are required for unit dismantling. Follow Section 3, 5, and Appendix 3, 4 for instructions.

6.3 Comformity with Recycling Regulations

• All dismantling procedures should be made in compliance with appropriate laws governing the recycling and disposal of materials.

• This machine may contain, but is not limited to:

1. Steel

2. Plastic

3. Rubber

4. Electrical Conductors

5. Aluminum

6. Paint

7. Magnetic Material

8. Nano-Fiber Filter

9. Dust and Debris from use

• Keep away from all mechanical moving parts including motor, gears, and other pinch points while operating.

Page 13

APPENDIX 1A - ELECTRICAL DIAGRAM MANUAL

[120 VAC] Single-Phase Power

ELECTRIC

SHOCK

HAZARD

[120 VAC 60 hz] Power Supply

WARNING Do not route auxiliary contact cable in the same conduit as motor cable

NOTE

Specic transformer wiring may differ depending on voltage conguration.

Disconnect power before performing any maintenance on unit, including filter inspection. The input power to this unit is high voltage, and touching any live electrical parts can cause fatal shocks or severe burns. Do not touch live electrical parts.

Motor

1.5 HP [120v]

TEFC Motor

60 Hz

Units in brackets [ ] refer to imperial system values

Page 14

APPENDIX 1B - ELECTRICAL DIAGRAM MANUAL

[230/460/575V] 3-Phase Power

ELECTRIC

SHOCK

HAZARD

[230/ 460/575v 60 hz] Power Supply

WARNING Do not route auxiliary contact cable in the same conduit as motor cable

NOTE

Specic transformer wiring may differ depending on voltage conguration.

Motor

3HP [230/460/575v]

TEFC Motor

3600 RPM 60 Hz

Units in brackets [ ] refer to imperial system values

Page 15

APPENDIX 2 - MAINTENANCE RECORD

DiversiTech Inc. authorizes this page to be photocopied or otherwise reproduced as needed for management of maintenance records.

MANUFACTURER: DIVERSITECH INC. MODEL N° FRED-JR SERIAL N°

SERVICE LOCATION: CONTROL N°

Date Description of Service Serviced By Location Comments

Only use manufacturer approved replacement parts on this unit.

Page 16

APPENDIX 3 - ARM-TO-BLOWER DIRECT INSTALLATION

3.1 Unpack capture arm, hood, and base

Capture Arm

Swivel Base

STEP 1. Unpack capture arm, hood, and base.

3.2 Attach swivel base to mounting plate

Vent Hood

STEP 2. Attach swivel base to mounting plate.

• Mount Swivel Base to Mount Plate.

• Tighten all Bolts (8) with Washers (8)

• Toque each bolt to 23 N m

Quantity

1 Mounting Plate

1 Swivel Base

8 1/4’’ Bolt, Socket Cap

8 1/4’’ Washer

Hardware

Page 17

3.3 Attach capture arm to swivel base

STEP 3. Attach capture arm to swivel base.

Quantity

1 Swivel Base

1 Capture Arm Assembly

3 1/4’’ Bolt, Socket Cap

Hardware

1/4’’ Washer

1/4’’ Locking Nut

1/4’’ Spacer

• Insert Spacers (3) between Capture Arm Mounting Bracket.

• Thread Bolts (3) with Washers (3) through Mounting Bracket and Spacers.

• Mount Capture Arm Assembly to Swivel Base.

• Thread Washers (3) and Locking Nuts (3) to Bolts (3)

• Tighten all Bolts (3) to Locking Nuts (3)

• Toque each bolt to 40 N m

Page 18

3.4 Install flex hose

STEP 4. Install flex hose.

• Mount Flex Hose to Swivel Base and Capture Arm.

• Tighten Both Hose Clamps.

APPENDIX 4 - FILTER INSTALLATION

4.1 Opening rear panel for filter access

Quantity

1 Fred-JR Assembly

2 Hose Clamps

1 Flex Hose

Hardware

STEP 1. Opening rear panel.

• Twist and release Twist Lock Latches.

• Open Rear Panel.

Quantity

1 Fred-JR Assembly

Hardware

1 Rear Panel

2 Twist Lock Latches

Page 19

4.2 Preparing for filter

STEP 2. Preparing for filter.

• Slide and lock the Locking Bolt in the left most position.

• Pull Retention Rod Handle to allow space for filter.

Quantity

1 Fred-JR Assembly

1 Locking Bolt

1 Retention Rod Handle

Hardware

4.3 Inserting filter

STEP 3. Insert clean filter.

Quantity

1 Fred-JR Assembly

1 Locking Bolt

1 Retention Rod Handle

1 Filter

Hardware

Page 20

4.4 Locking filter

STEP 4. Locking filter.

• Push Retention Rod to forward most position

• Slide and Lock the Locking Bolt to the right most position and lock.

4.3 Closing rear panel for filter access

Quantity

1 Fred-JR Assembly

1 Locking Bolt

1 Retention Rod Handle

1 Filter

Hardware

STEP 5. Closing rear panel.

• Close Rear Panel.

• Twist and release Twist Lock Latches.

Quantity

1 Fred-JR Assembly

1 Rear Panel

2 Twist Lock Latches

Hardware

Page 21

APPENDIX 5 - PARTS LIST

Description Part No. Quantity

1 Filter Access Door Latches INV-HARD-0446 2

2 Filter Access Door - 1

3 Filter, Carbon Activated Panel INV-FILT-0401 1

Filter, Nano-Fiber, 99.99% efficient @ 0.5 microns INV-FILT-26NF standard

Filter, HEPA, 99.97% efficient @ 0.3 microns S-FILT-0303 optional

5 Cabinet - 1

6 Mounting Plate - 1

7 Handle - 1

8 Front Door - 1

9 Manual Starter Enclosure w/ Control Switch INV-CAST-0090 1

10 4” Swivel Caster w/ Brake INV-CAST-0028 2

11 10” Rubber Wheel INV-CAST-0031 2

12 Blower Wheel Assembly - 1

Page 22

APPENDIX 6 - SAMPLE SAFETY STICKERS

The machine is marked with a wet filtration safety sticker to remind the operator of safe working practices:

The machine is marked with safety stickers in appropriate places to remind the operator of safe working practices.

Page 23

NOTES

Page 24

LIMITED EQUIPMENT WARRANTY

For a period of 2 years from the date of purchase, all Diversitech products are warranted to be free from defects in material, workmanship, and construction, when used in accordance with installation, maintenance instructions, and expressly stated proper use application(s). Diversitech Inc. will repair or replace, at our option, any defective parts which fail during the warranty period. This warranty is limited to replacement parts ONLY, and does not cover personal liability, property loss, normal wear; and does not cover losses resulting from (or due to) improper installation, inadaqueate maintenance, misapplication, misuse, or use above rated capacities.

FREIGHT CLAIMS

Shipments must be inspected upon arrival. All Diversitech units are sold ex-plant. Therefore, it is the receiver’s responsibility to file any freight claims with the carrier for obvious or concealed damages. Damaged shipments must be refused at time of receipt, by consignee.

RETURN MATERIAL POLICY

Prior to the return of material, for whatever reason, a return manufacturing authorization number (RMA#) is required from the Diversitech customer service department. This procedure is necessary for proper control and handling of returned materials. Call 1-800-361-3733 or email [email protected] to obtain an RMA.

All material must be returned prepaid. Credit will be given for returns for warranty repair or replacement. Freight collect shipments, or freight without an RMA, will not be accepted. It is the shipper’s responsibility to ensure that material being returned to Diversitech is adequately packaged for shipment to preclude damages.

DIVERSITECH

Visit our Website for more information on this product

www.diversitech.ca

2500 Alphonse Gariepy, Montreal, Quebec H8T 3M2 Email: [email protected]