Nederman FilterMax F, FilterMax F 30, FilterMax F 90, FilterMax F 60 Instruction Manual

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INSTRUCTION MANUAL

ENGLISH

0 1

CAPTURE AT SOURCE

No. 148546 / 03 2006-10-01

List of contents

CE, Declaration of conformity

page 3

Installation

Operating

Starting

Settings

Service

Repair

Delivery check IMPORTANT! Safety imformation Pre-installation Technical data Dimensions Mounting instructions Mounting the filter cartridges Compressed air connection Electrical installation Accessories, electrical installation Earth control measuring Applications Wiring diagram Connection of several FilterMax to one system Connection of 2 or 3 pilot boxes Fans Duct dimensioning / System installation

Operating description

Starting the system Monitoring system, settings Monitoring system, general descriptions

Monitoring system, fault indications Service instructions Trouble-shooting schedule Spare parts

3 4 4 4 5 6 7 8 9 9 - 11 12 12 13 14 15 15 16

18 18 - 19 20

21 - 22 23 - 25 26 - 28 29

Accessories

Protocols

Accessories

Installation protocol Service protocol Service notes

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31 - 32 33 - 36 37

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FilterMax F 30

FilterMax F 60 FilterMax F 90

This product is designed to meet the requirements of the relevant EC directives. To maintain this status all installation, repair and maintenance work must be carried out by qualified personnel using only original spare parts. Contact your nearest authorised dealer or AB Ph. Nederman & Co. for advice on technical service or if you require spare parts.

AB Ph. Nederman & Co.

Sydhamnsgatan 2 S-252 28 Helsingborg Sweden 2006-10-01

Lennart Andersson, Product Manager

DELIVERY CHECK

The following modules should be mounted together to assemble the complete FilterMax F. When delivered A - C are already assembled (units shipped by sea may contain more components).

A. Filter unit (1, 2 or 3 pcs.) B. Stand C. Control box D. Collector (2 x 40 litres or 2 x 100 litres

with stand extentions)

E. Inlet F. Outlet G. Filter cartridges

(6 pcs./filter unit)

Declaration of conformity

We, AB Ph. Nederman & Co., declare under our sole responsibility that the Nederman product: FilterMax F serial 667 with accessories, to which this declaration relates, are in conformity with the following directives, underlying standards or other normative documents: Directive: 98/37/EC - Safety of machinery Applied standards EN 292 Part 1,2, EN ISO 4871 Directive: 89/336/EEC - Electromagnetic compatibility. Applied standards EN 50082-1, EN 61000, EN 55011 and EN 55022 Directive: 73/23/EEC - Low voltage equipment. Applied standards EN 60204-1,EN 60947-1 Directive: 87/404/EEC - Simple pressure vessels Applied standards EN 286-1 part 1

The units should be checked for any damage that may have occured during transport. If there is damage or parts missing, the carrier and your local Nederman representative should be notified immediately.

FilterMax F can be supplemented by a number of accessories (see page 30).

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IMPORTANT! SAFETY INFORMATION

Nederman FilterMax F is designed for collecting and filtering fume and non-explosive dry dust.

To guarantee the correct function and a minimal service FilterMax F must only be used for these purposes and according to the instructions in this manual. 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.

For safe and reliable results assembling work, electrical installation, use, service and trouble-shooting should be performed by qualified personnel. Special training may also be necessary.

Please contact your nearest authorised dealer or AB Ph. Nederman & Co. for technical advice.

PRE-INSTALLATION

FilterMax FI is for indoor installation. FilterMax FO is for outdoor installation. FilterMax F should be located with consideration for easy handling of the collected dust and for convenience of service and maintenance.

FilterMax F is usually installed on a reinforced concrete foundation. However, installation on another structure is also possible. When calculating for foundation or supporting structure the following factors should be taken into consideration (see technical data):

• Total weight of FilterMax F

• Max. weight of collected contamination

• Possible wind load

• Possible snow load

IMPORTANT! Location must be clear of all obstructions such as utility lines etc. Pay particular attention to the

anchor bolt location. Anchor bolts (M16) must extend at least 60 mm above foundation. If you intend to secure the unit by using expansion bolts or equivalent fittings, the concrete floor must be prepared accordingly.

max. 155°

1200

min. 100

min. 5001000

FILTERMAX

1320

967

TECHNICAL DATA

Filtration

Operating airflow

Filterarea / filter cartridge Filter material Operating temperature Process air (dry) temperature Material description Environment classes *

Compressed air requirements Compressed air consumption Compressed air connection Voltage supply Protection class Relay voltage, accessory Working pressure Pulse noise Weight

Basic PW filter: 99% at 0,3 µm (after some time in operation), BIA class C PTFE filter: 99,9% at 0,3 µm (after some time in operation), BIA class C 1 module: 2400 - 3600 m3/h (depending on load and application) 2 modules: 4800 - 7200 m3/h (depending on load and application) 3 modules: 7200 - 10800 m3/h (depending on load and application) 1 module: 60 m2, 2 modules: 120 m2, 3 modules: 180 m 2 layer polyester / polypropylene

-20°C to +60 °C 0 °C to +60 °C, not condensing 3 mm painted steel (FilterMax FI, FO), epoxy based zinc primer and top coat (FO only)) C2 = low corrosion risk, indoors, unheated air varying temperature (FilterMax FI) C4 = high corrosion risk, outdoors polluted urban areas and coastal areas (FilterMax FO) 0,6 MPa (6 bar, 87 psi), water and oil free 32 N-litres / cleaning pulse at 0,6 MPa (6 bar, 87 psi) 1/2" R 15, max. 0,6 MPa (6 bar, 87 psi) 100 V, 120 V, 230 V, 50/60 Hz IP 54 24 V AC, max. 60 VA 0 to -5 kPa, not overpressure Lp Aeq, 30 s, 50 dB 1 module: 615 kg, 2 modules: 890 kg, 3 modules: 1150 kg

*according to EN ISO 12944

DIMENSIONS

3 MODULES

2 MODULES

OUTLET

1 MODULE

ABC

135

INLET

2270 3190 4120

115

1180

open angle 155

1515 1690

1320

970

1030

1160

2 x 40 litres containers

NB!

The height dimensions for the filter are only valid when using the 40 litres containers.

In/Outlet inner diameters (mm)

500

400

2440 3365 4290

3540 4470 1445

395

2565 3490 4415

4600 1465

445

A B C D E F G H

250

2450 3370

275

315

2375 3300

2560 3480 4410 1430

325

130

MOUNTING INSTRUCTION

WARNING!

Risk of personal injuries and/or product damages!

Use approved lifting equipment for unloading, assembly and installation

of the units.

0 1

Use schackles, not hooks on the lifting sling.

x 3

Connect the lifting sling to 4 cabinet lifting lugs. Distribute loads equally.

NB! Maximum 2 units should be lifted at the same time.

IMPORTANT!

Ensure that the inlet, outlet and all filter units always are mounted together with bolts in all intended holes. Always use toothed washers to ensure electric connection.

1. Mount the dust containers. If dust containers

2 x 100 litre should be mounted the stand extensions also must be mounted.

2. FilterMax is usually anchored to a concrete foun-

dation with expansion bolts or similar. Fit the fixing bolts and use adjusting pieces, if necessary, to get the filter unit in level. Check with a spirit level.

For more stabilty, the filter unit can be braced against the wall.

3. For FilterMax F 60 and F 90 two and three

filter units are used respectively. Mount the units together to build the complete filter unit.

NB! The inlet and outlet are reversable and concequently they can be positioned for duct connection on the right or left side of the filter.

4. Fit the inlet and outlet.

(NB! The inlet is equipped with an inspection cover on top.)

MOUNTING THE FILTER CARTRIDGES

1. Unscrew the two fixing screws on the

access door. Use the enclosed T-key or a 10 mm standard hexagon key. Open the door.

2. Loosen the nuts

on the filter holders but don’t screw them off completely. Remove the filter holders.

3. Handle the filter cartridges carefully to

avoid mechanical damage to the filter surface.

4. Insert the filter

cartridges. NB! The mark on the back end cap should be put on the angled sheet-metal plate just inside the filter hole.

WARNING!

Risk of personal injury!

For FilterMax F equipped with 2 or 3 modules (12 or 18 filter cartridges), an approved lifting platform (see figure) has to be used when mounting or replacing the filter cartridges.

5. Hang the filter holders on the screws

and fasten the nuts.

6. Shut the access door and

fasten the two fixing screws.

COMPRESSED AIR CONNECTION

Connect the compressed air supply line to the compressed air connection of the filter. Use pipe sealant on all compressed air connections.

Compressed air components

(accessories, see page. 30) A shut off valve for service work and a

filter regulator should be installed in the compressed air pipe line (Note the flow direction during the installation).

Important! the filter regulator must be positioned in a frost free environment.

Recommended connection size: minimum 1/2".

Compressed air tank, module no. 3

Water drain valve

Compressed air tank, module no. 2

Water drain valve

FilterMax F Control box

Pressure switch (accessory)

Service valve with integrated drain valve (accessory)

Filter regulator, recommended pressure 0,5 MPa (5 bar / 73 psi) (accessory)

Compressed air connection

Compressed air tank, module no. 1

Water drain valve

IMPORTANT!

• The compressed air supply pressure has to be = 0,4 - 0,6 MPa (4 - 6 bar / 58 - 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 connecting to the compressed air manifold.

• Do not use thread-sealing tape after the filter regulator.

• Quick couplings throttle the air too much and are not recommended.

• Turn off and bleed off compressed air supply before doing any service work.

• Do not pressurise the system if the air tem perature is below the minimum operating temperature, that is -20 °C. At lower air tem perature the process could be started and be in operation for a while (approx. 15 min.) after which the system can be pressurised.

ELECTRICAL INSTALLATION

IMPORTANT!

All electrical work must be done by a qualified

WARNING!

Risk of personal injury!

Disconnect the electrical power before servicing any electrical component.

All exposed conductive parts of the electrical equipment and the machine shall be connected to the protective earthing (see wiring diagram).

electrician according to local regulations.

Connect FilterMax F to the mains and connect fan and other components and accessories according to the following wiring diagrams.

A lockable safety switch should be fitted on the mains connection cable.

Electrical connection together with Nederman Fan Starter or Fan Inverter is described on wiring diagrams supplied with these products.

ACCESSORIES, ELECTRICAL CONNECTION

Connecting fan and other accessories to the FilterMax F as well as connecting the FilterMax F to the mains must be done by a qualified electrician.

Connection block JP 1: Digital inputs

External START/STOP

Pressure switch, compressed air

High dust level

Pressure switch, high dP / low airflow / simple dP control

Spare, not used

Fan motor protector

Fire alarm

14 109876532

97 98

Dielectric detector PNP

132

> P

JP1

The accessories must be equipped with a potential free contact

Connection block JP 6: Outputs

Max. 2 A

Fan starter (24 V AC)

Down time damper (24 V AC)

Dust feeder (24 V AC)

Automatic depressurising of compressed air tanks at fire

Alarm signal (A or S), 24 V AC

A-Alarm, potential free contact, 24 V AC

Fan starter potential free contact, 24 V AC

14 10119876532

Alarm device

Start contactor

Damper motor

JP6

Compressed air tank on FilterMax F

P > 3 bar

Fan start equipment

Pressure switch

Automatic depressuring of compressed air tanks at fire

Frost free

Normally closed valve with big bore.

Normally opened valve.

Compressed air connection.

Filter regulator

Both valves shall be connected to JP6:4, 10/11, so they will be activated (drawn) at normal operation. At a possible fire alarm (or a power failure) the valves are switching and the compressed air tanks will be depressurised.

ACTIVATING THE MENU

0 1

Push the P-button and the 0/1-button more than 4 seconds.

ACTIVATING INPUTS AND OUTPUTS

The inputs or outputs should be activated when accessories have been connected. Push the P-button to activate actual input/output. The LED’s indicate, where appropriate, with red blinking lights.

The inputs are activated in the following order:

Selecting OFF, nC or nO

Push the 0/1-button and OFF, 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.

or nC or nO

OFF

Red blinking

OFF

Red blinking

OFF

or nC or nO

Motor protector, fan

Push the P-button. Activated input: JP1: 6 Set OFF, nC or nO with the 0/1-button.

OFF nC nO

High dust level indicator

Push the P-button. Activated input: JP1: 3 Set OFF, nC or nO with the 0/1-button.

OFF nC nO

Pressure switch, compressed air

Push the P-button. Activated input: JP1: 2 Set OFF, nC or nO with the 0/1-button.

OFF nC nO

OFF

Red blinking

or nC or nO

Red blinking

Pressure switch high dP / low airflow

Push the P-button. Activated input: JP1: 4 Set OFF, nC or nO with the 0/1-button.

OFF nC nO

EA OFF

or nC or nO

Fire alarm

Push the P-button. Activated input: JP1: 7 Set OFF, nC or nO with the 0/1-button

OFF nC nO

or OFF or Int

dF On

00 - 60 s

dA 00

or OFF

LO ON

Dust feeder

Push the P-button.

Activated output: JP6: 3 Direct controlled by contactor or other 24 V relay.

On: The dust feeder is in operation OFF: The dust feeder is not in operation

Int: Intermittent operation of the dust feeder Set On, OFF or Int with the 0/1-button.

On OFF Int

Down time damper delay

Push the P-button. Activated output: JP6: 2 24 V AC supply for opening a damper motor with spring return or magnetic valve for compressed air. Is used to reduce the starting current at fan start. Delay time for opening the down time damper: 10 - 60 s after fan start. Set the required delay time with the 0/1-button.

Local START/STOP

Push the P-button. Activated input: JP1: 1 Inactivates the start/stop button on the control box. Only remote start is possible in OFF-position. Set On or OFF with the 0/1-button.

On OFF

or FAN

PULSE

Red fixed light

In the Fan start mode

Start signal Stop signal

In the Pre-coate mode

ST PA IN PA IN PA

Start signal

Stop signal

Pre-Coate Control

In some applications with FilterMax it is necessary to inject dust. The purpose can be to reduce the fire risk or improve cleaning of the filter cartridges. The input JP6:1 can be used in 2 ways. When the function of the motor protection has been chosen, the fan LED will show fixed red light. Then you are able to choose the use of JP6:1 PULSE or

FAN with the 0/1-button. PULSE is the pre-coate mode.

PULSE FAN

If PULSE is set there will be a choise of parameters to set: ST - Start. The initial injection time: 0, 1, 2, 3, 4, 5, 7, 10,

15, 20, 30, 40, 60 or 90 s. IN - Injection. The injection time: 0, 1, 2, 3, 4, 5, 7, 10, 15, 20, 30, 40 or 60 s. PA - Pause. The pause time between the injections: 0 or 20 s. 1, 2, 5, 10, 20 or 60 min.

If FAN is set JP6:1 will run in parallel with JP6:8,9 serving as a 24 V fan start signal.

EARTH CONTROL MEASUREMENT

Earth control measuring must only be done by a person with necessary knowledge.

IMPORTANT!

All metal parts of the filter unit must be earthed reciprocally and connected to earth. To secure this, the following procedure must be followed.

When the FilterMax F has been installed and during maintenance work the earthing shall be measured. The measuring is done between GND1 (in the Control Box, see picture below) and the following components on FilterMax F. Disconnect protection earth from GND1 before measuring.

1. Inlet

2. Cleaning access point (on the inlet)

3. Dust container

4. Adapter for dust container

5. Filter cartridge

6. Filter module

7. Door Reconnect protection earth to GND1.

Circuit card FilterMax F Control Box

JP3 230

120 100

0 1

GND1

APPLICATIONS

Nederman FilterMax F separates for instance welding fume, metal oxides, talcum, lime stone, dust and grinding dust.

FilterMax F must not be used for separating explosive contaminations.

Explosive dusts are dry organic dusts and some metallic dusts. The metallic dusts are, for example, aluminium, magnesium, titanium, chromium and fine virgin dusts of other metals. Welding fumes from these metals are not explosive, but grinding dust is a problem. Please contact your Nederman representative in case of doubts.

Various combinations of semi combustible fumes/dusts (oil, grease) and sparks can cause fires when grinding or welding. The most important action is to prevent sparks from entering the extraction devices. Secondly it is very important to perform regular cleaning of the extraction arms/devices and the duct system.

FilterMax F does not separate gases.

Disconnect at earth

control measuring

WARNING!

Risk of personal injury!

• In some countries the purified air must not be recycled in the workshop if FilterMax F is used to separate welding fume or some contaminations that may be a health hazard.

• Use a safety filter if the air is recycled in the workshop.

Risk of fire or explosion!

• Do not use FilterMax F to separate explosive fume or dust.

• Connect a fire alarm to the filter controling processor, which means the filter will stop at a possible fire.

• Care should be taken when working with painted or oiled material. Consult your Nederman representative for advice.

• FilterMax F must not be exposed for burning/ glowing material.

CONNECTION TO THE MAINS

WIRING DIAGRAM

Pilot box

CONNECTION OF:

• FAN STARTER

• SAFETY SWITCH (Nederman accessory)

• AFTER CLEANING DAMPER

• PRESSURE SWITCH (Nederman accessory)

• PILOT BOX (included in the delivery)

• FAN (Nederman accessory)

NB! After cleaning damper with spring

return should be connected only to JP6 no. 2 and no.10 or 11.

Motor After cleaning damper

Fan contactor Control voltage 24 V 2 A max

135

246 135

246

135

246

Open

Supply

Com

95 97

96 98

JP5

JP6

1 2

1 2 3 4 5 6 7 8

9 10 11

F8 F7

Designations, Circuit card FilterMax F control box:

JP1: Inputs JP3: Power supply JP4: Pilot box JP5: A-alarm off JP6: Outputs

Circuit card FilterMax F Control box

123456789

JP1

NB! connection

between 3 and 4

JP4

Door

{

Pilot

control

Brown

JP3 230

120 100

GND1

Output

Input

Black

Blue

Connection of 2 or 3 pilot boxes, see page 15

Door switch

For fan start, two alternatives are possible. Alternative 1: Connection to block JP6: 1 (24 V AC), for direct control by contactor or other 24 V relay. Alternative 2: Connection to block JP6: 8 - 9, potential free relay output, is used when the start equipment has its own 24 V control voltage, for example Nederman Fan Starter (which is recommended). The complete connection is described in the Fan Starter Instruction Manual.

BASIC FUNCTIONS

1. Down time damper

Alt. 1. Electric motor open and close

Alt. 2. Electric motor open, Spring return Alt. 3. Magnetic valve for compressed air operated damper with spring return.

2. Transformer

FilterMax F

Wire to JP6 : 2 and 10 or 11(common) and the lower 24 V AC output from the transformer (2).

Wire to JP6 : 2 and 10 or 11(common).

> P

Pressure switch

Fuses F1: T 1 A, 230 Vac power supply

F2: T 1,6 A, 120 Vac power supply F3: T 2 A, 100 Vac power supply F4: T 2 A, 100, 120, 230 Vac power supply F5: 2 A, Basic card, inputs, dP card and

operator terminal power supply F6: 2 A, Basic card, inputs, dP card and operator terminal power supply

F7: 2 A, Outputs power supply F8: 2 A, Outputs power supply

Mains-connection

100/120/230 V,

PE, 50/60 Hz

3. Pressure switch, compressed air

FilterMax F - Wire to JP1 : 2 and 9 or 10(common). Select nO in the software setting if an OPEN contact indicates OK. Select nC in the software setting if a CLOSED contact indicates OK.

CONNECTION OF TWO FILTERMAX TO ONE SYSTEM

LINE 1

0 1

LINE 2

LINE 1 LINE 2

0 1

NB! connection between

3 and 4 on the last pilot box.

NB! Remove the connection between 3 and 4 on the output contact before the cable from the pilot box above is connected.

JP5

1 2

JP6

1 2 3 4 5 6 7 8

9 10 11

Circuit card FilterMax F Control Box

123456789

JP1

Door

Pilot

control

GND1

JP4

{

3 2

JP3 230

120 100

IN OUT 4

3 2

4321

4 3 2 1

IN OUT

4 3 2 1

GND to filter house

4321

4 3 2 1

GND to filter house

NB! connection between 3 and 4

CONNECTION OF 2 OR 3 PILOT BOXES

JP4

4 3 2 1

NB! Remove the connection between 3 and 4 on the output contact before the cable from the pilot box above is connected.

NB! connection between 3 and 4 on the last pilot box.

Total pressure

4000

3000

2000

NCF 40/25

NCF 30/25

NCF 30/15

FANS

NCF 160/25

NCF 120/25

NCF 50/25

NCF 80/25

NCF 80/15

NCF 120/15

1000

Each FilterMax F can be connected to an existing central fan or to a fan dimensioned specially for the system.

An adequate fan can be selected from the Nederman NCF-range. Please contact your

2000 4000 6000 8000 10000 12000 14000 m /h

Air flow

Nederman representative for dimensioning the right fan capacity.

Calculated air pressure drop over the filter is approximately 1200 Pa.

STARTING THE SYSTEM

1. Turn on the compressed air supply to the cartridge filter.

Adjust to 0,4 - 0,6 MPa (4 - 6 bar, 58 - 87 psi) of pressure. Pressure of 0,5 MPa is the most typical setting for satisfactory cleaning performance.

2. Close the regulating damper halfway, see figure, page 16. (As an alternative the airflow can be controlled by a Nederman FanInverter).

3. Start the fan and check fan impeller rotation. Refer to 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.

WARNING!

Risk of personal injury!

Stand clear of blower fan exhaust area as debris can be exhausted and cause injury.

4. IMPORTANT! It is necessary to adjust the airflow to the dimensioned value using the regulating damper (or Nederman FanInverter). The air flow can be measured

with a fixed airflow meter (or a pitot tube) and a micromanometer.

IMPORTANT! Too much airflow can dramatically reduce the life of the filter element.

Impeller rotation direction

5. All the solenoid valves should open and close continuously with a set interval time between each cleaning pulse (factory set of 30 seconds).

Check operation of the solenoid valves in the following way: Set the pause time on tst (see below). NB! This is only a control setting and should not be used for normal operation. Start the system and count the number of air pulses. It should be 6 pulses per module.

NB! Return the pause time to the original value after checking.

MONITORING SYSTEM, SETTINGS

CLEANING DURING OPERATION

FilterMax F is in its standard design equipped with a fully automatic compressed air cleaning of the filter cartridges. A piping system directs, by a system of solenoid valves, air pulses of 100 ms into the filter cartridges. The pause time between the air pulses is factory set at 30 s, but can be set between 5 s and 90 s. Shorter pause time can be used if more than 1 module is used or if FilterMax F is used for heavy load.

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.

• Normal load - Applications such as welding fume or light dusts in heavy concentrations.

• Heavy load - Typically metal cutting with laser or plasma and heavy welding.

With light load the cleaning pressure could be reduced to 0.4 MPa (4 bar). Check that the filter pressure drop does not rise too quick. If so, the pause time could be reduced with one step and the cleaning pressure could be increased, but maximum to 0.6 MPa (6 bar).

Model / Dust load

FilterMax F 30 FilterMax F 60 FilterMax F 90

The factory setting is 30 s for all FilterMax F. * or no on line cleaning

pt 30

Setting the pause time

Push the P-button until pt is shown in the display. Set one of the following values for pause times with the 0/1-button. tst = test position, all valves will be opened 1 time with 1 s interval.

tst 10 s 15 s

20 s 30 s 45 s

Light

90 s *

60 s 30 s

Normal

60 s 30 s 15 s

60 s 90 s No cleaning

during operation

Heavy

30 s 15 s 10 s

0 1

CLEANING AFTER OPERATION

It is possible to choose cleaning after operation, that is when the fan has stopped. This is more efficient

than cleaning during operation and is therefore recommended. The pause time at cleaning after

operation is always 15 s. If cleaning after operation has been chosen, one

has to set the desired number of cleaning cycles,

where one cycle means the cleaning of all filter cartridges, that is 6, 12 or 18 cartridges, depending on the number of modules in operation. 2 - 3 cycles are recommended depending on the dust load (light - normal) When cleaning after operation it is recommended to use an after cleaning damper (see accessories page 30).

dt 3

A-ALARM FUNCTION

The alarm-function is always ON when the system operates, which means if there are negative

or Go

dL StP

Setting the cleaning cycles

Push the P-button until dt is shown in the display. Set the desired number of cleaning cycles with the 0/1-button.

0 1 cycle 2 cycles

influences on the function during operation, the alarm will release, that is LED no. 7 will show a red fixed light.

3 cycles 4 cycles 5 cycles

Setting the alarm-function

Push the P-button until dL is shown in the display. Choose any of the functions Go or StP with the 0/1-button. For fume/ dust generating processes that can’t be stopped immediately when a fault accurs it is recommended to set Go and that a clearly visible alarm device is installed. Go: The system does not stop when the A-alarm is activated, with exception for explosion/fire-alarm, motor protection and with the access door open. The system always stops for these functions. StP: The system stops automatically when the alarm is activated.

REMOTE START

It is possible to choose the functions Aut or OFF with the 0/1-button. For most filters that are remotly started from a machine or a process eg. it is convenient to choose Aut.

or OFF

rE Aut

The remote start control should be connected to JP 1 and 9 or 10 (see page 9). If remote start is used, the system can not be stopped with the 0/1-button. The text rE is shown in the display for a short time.

Remote start, setting

Push the P-button until rE is shown in the display. Choose Aut or OFF with the 0/1-button. OFF: When using remote start there is no automatic restart when a fault has been rectified. The remote started mashine must be stopped and the FilterMax F must be reset by one push on the start button before a new remote start can be done. Aut: When using remote start there is automatic restart when a fault has been rectified or after a power failure.

MONITORING SYSTEM, GENERAL DESCRIPTIONS

The LED:s can indicate the following:

1 2 3 4 5 6 7

The display on the control box gives information about the number of operating hours, cleaning process, alarm functions and possible faults.

Blinks when the cleaning function operates.

1, 2, 3, 4, 5 green fixed light: All functions normal and correct

1, 2, 3, 4, 5 green fixed light alternating with blinking red: The system operates. Incorrect function has been rectified (alarm memory) 1, 2, 3, 4, 5 red fixed light: Incorrect function which

requires investigations. 6 yellow fixed light: Incorrect function which requires attention. 7 red blinking light: Incorrect function which requires immediate investigations. 1, 3, 4, 5 is only active after the inputs for the accessories has been activated (see page 10).

0 1

Fixed red light when the system operates.

1 2 4

r E

Both "point" and 11 blinks when cleaning after operation is in progress.

The total number of operating

hours are displayed.

r E is displayed when trying to stop the system from the control box when

the system is remote started.

The system has stopped and the cleaning after operation is active. If the 0/1 button is pressed once more the cleaning after ope-

ration is stopped immediately.

MONITORING SYSTEM, FAULT INDICATIONS

The fan motor overload protector is released. Check the cause. Rectify the fault and reset

Red blinkingRed fixed

light

the motor protector. FilterMax F always stops when the motor protector is released.

Red

fixed light

Red fixed light

Yellow fixed light

Red blinkingRed fixed light

Possible faults (depending on how the input has been used):

1. The pressure drop over the filter is high.

2. The air flow in the system is too low.

• Check if the filter cartridges are saturated, change if necessary.

• Check if any damper is not open enough.

• Check the inlet for dirt. Clean if necessary.

Low pressure in the compressed air supply. FilterMax F will not start.

FilterMax F has stopped due to low compressed air pressure (less than 0,4 MPa (4 bar)). FilterMax F will not start until correct pressure is resumed.

Red blinking

0 1

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 1 valve is defective or does not work. It is displayed which valves that are defective (Err +

1, 2, 3, ........ 18) are displayed, alternating with the

number of operating hours).

• Electronic faults on the circuit card.

Fire alarm. Call for service technician. Check the reason and do not start the system until the fault has been rectified.

Red fixed light

Yellow fixed light

Red blinkingRed fixed light

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 defect (Err + the defective valve no. (1 - 18) is displayed, alternating

with the number of operating hours.

0 1

The door has been opened during

system operation. Shut the door.

The door is open and FilterMax F

will not start.

Red fixed light Yellow fixed light

r E A

light

p F a i l

Red blinkingRed fixed

Yellow fixed light

The dust container is full.

Empty the container.

r E A is diplayed (alternating with the number of operating hours) in combination with a motor error and a desplayed

A-alarm at remote controlling.

There has been a power failure. Reset by pressing the 0/1-button. If the filter is remotely started it will start

directly when the 0/1-button is pressed.

or another digit

Err 0

See B, Trouble-shooting Schedule,

page 26

SERVICE INSTRUCTIONS

In order to ensure that the system continues to operate correctly, the following should be checked at periodic intervals depending on what kind of contaminations that are separated and the amount of use. Defective and worn parts should be replaced immediately.

EMPTYING THE DUST CONTAINER

IMPORTANT!

Empty the dust containers when they are approximately 70 % full. Do not let them overfill. It can cause poor filter performance and cause an extensive clean up work due to overflow of dust when removing the containers.

Normal working light is required for emtying the containers. Inspect how much the containers have been filled in the

beginning of the filtering process, to make it possible to estimate a normal emptying interval.

1. Switch off the FilterMax F.

2. Put a pallet, which can be operated by a lift truck, under

the dust containers.

3. Loosen the dust containers by realising the excentric

locks. Let the containers down to the pallet.

4. Empty the dust containers. Disposal of dust should be

in accordance with local regulations.

5. Check that the gasket between the filter and dust

container not is damaged.

6. Put the dust containers back under the filter and fit

them with the excentric locks, Check that the gasket between the filter and container is correctly fitted and seals after locking.

WARNING!

Risk of personal injury!

Use protective goggles, breathing mask and gloves when doing servicing and repairing work inside the system, specially when replacing the filter cartridges and emptying the dust containers.

Avoid contact or exposure to dust as much as possible during servicing or maintenance.

Shut-off and bleed compressed air supply before opening the inspection door and servicing any compressed air components.

Disconnect electrical power before servicing.

CHECK WHEN EMPTYING THE DUST CONTAINER

Check if there is water (or oil) in the filter regulator. In that case, the compressed air is not dry enough and there is a risk of damage to the filter cartridges. Check that the pressure is set to 0.4 - 0.6 MPa (4 - 6 bar, 58 - 87 psi). If there is water in the filter regulator container, check that there is no water in the pressure tank (tanks), by opening the drain nipple on the right bottom side of the tank.

Filter regulator container

SERVICE AFTER 1000 OPERATION HOURS, BUT AT LEAST ONCE EVERY 6TH MONTH

• Check that all valves in the cleaning system operate properly. Count the number of air pulses, 6 per module, that is 6, 12 or 18 per cycle.

• Remove dust collections from the lower part of the clean air room.

SERVICE AFTER 2000 OPERATION HOURS, BUT AT LEAST ONCE A YEAR OR WHEN REPLACING FILTER CARTRIDGES

• Unscrew the inspection cover on top of the inlet. Check the seals. Clean when necessary.

• Check that there is no water in the pressure tank (tanks), by opening the drain nipple on the right bottom side of the tank.

• Check the filter cartridges. They should be replaced if the outer surfaces are damaged or if the air flow through FilterMax is insufficient due to saturation of the filter cartridges despite repeated cleaning.

• Take measures against possible corrosion by grinding, primer and touch up paint.

• Earth control measurement (see page 12) GND1 - Inlet GND1 - Inlet cleaning access cover GND1 - Dust container GND1 - Dust container adapter GND1 - Filter cartridges GND1 - Filter units GND1 - Doors

REPLACING THE FILTER CARTRIDGES AT DAMAGE OR INSUFFICIENT FILTER FUNCTION, BUT AT LEAST AFTER 6000 OPERATION HOURS

Inspection cover

WARNING!

Risk of personal injury!

For FilterMax F equipped with 2 or 3 modules (12 or 18 filter cartridges), an approved lifting work platform (see figure) has to be used when exchanging the filter cartridges.

Instructions for replacing the filter cartridges, see next page.

After 6000 operating hours, also check that the cables not are damaged or connected incorrectly.

REPLACING THE FILTER CARTRIDGES

1. Switch off the FilterMax F.

2. Shut off and bleed the compressed air.

3. Unscrew the two fixing screws on the

access door. Use the enclosed T-key or a 10 mm standard hexagon key. Open the door.

4. Loosen the nuts

on the filter holders but don’t screw them off completely.

8. Remove the mounting frame

and fold the plastic bag in a way

5. Remove the

filter holders.

that the filter cartridge will be completely enclosed and sealed.

9. Proceed in the same way with the

remaining filter cartridges.

7. Hang the mounting frame

with the plastic bag over the end of the filter cartridge. Draw the whole cartridge in to the plastic bag.

10. Inspect the filter housing and look for damage,

dust layers etc. Clean inside the filter housing. A vacuum cleaner is recommended.

11. Handle the new filter cartridges carefully

to avoid damage.

12. Insert the new filter cartridges. NB! The mark on the

back end of the filter cartridge should be put on the angled sheet-metal plate just inside the filter housing.

13. Hang the filter holders on the screws and

fasten the nuts.

14. Check the access door seal. Shut the door and

fasten the two fixing screws.

15. Turn on the compressed air supply.

6. Draw a plastic bag

through the opening in the enclosed mounting frame, as the picture shows.

TROUBLE-SHOOTING SCHEDULE

FilterMax F will not start.

Are there any LED’s on the controlbox panel that are on.

YES

Is the A-alarm LED no. 7, on?

Possible faults

Control questions

Actions

IMPORTANT!

• Turn off the compressed air supply with the service valve before doing any work on the cleaning system.

• Do not pressurise the system if the air temperature is below the minimum operating temperature (= -20 °C). At lower air temperatures the process can be started and operated for a while (approx. 15 min.) whereafter the system can be pressurised.

Check the fuses on the card and the power supply to the card. If the power supply and the fuses are fully functional, contact your nearest Nederman representative for more assistence.

FilterMax F starts, but stops after a while and the display shows Err + a digit.

Is the display showing Err 0 ?

YES

The cable connecting the controller to the first pilot box is not properly connected.

Are you trying to remote start the filter?

Contact your nearest Nederman representative for advice.

YES

Is the display showing Err + another digit than 0 ?

Contact your nearest Nederman representative for advice.

YES

Correct the error indicated by the function LED’s, see page 21 - 22.

Check that the wiring is correct. Closing 1 + 9 or 10 shall start the filter.

There is an electrical fault in one or more of the pilot valves. The number/s shown after Err are the number of the faulty valve/s.

Depressurise the system. Check that the leads to the valve coil are properly connected. Remove the leads and measure the resistance of the coil, it shall be approximately 26 Ω . If the resistance is more than 29 Ω or less than 23 Ω or if the coil circuit is cut, replace the pilot valve.

FilterMax F starts, but the fan will not start.

Check that the electrical wiring for the fan start is done correctly between 1 and output common (10 or 11) on the outputs (block JP6). See wiring diagram, page 13.

The FilterMax F pressure resistance is high.

Is the cleaning system fully functioning?

YES

Check the pressure of the compressed air. It should be 0,4 - 0,6 MPa (4 - 6 bar, 58 - 87 psi).

Are there some valves that are functioning?

Go to B

The airflow is insufficient.

Is the pressure resistance high ( >1000-1500 Pa)?

YES

Go to F

If the ∆ P Control is installed go to the ∆ P Control manual section regarding the adjustment of cleaning the system.

Otherwise, check the pause time set on the timer (see page 18). The default value is 30 s. A heavy application or a 2 - 3 module unit (12 - 18 filter cartridges) will require shorter times. A very light application can use longer times.

If the cleaning has been adjusted previously you may have to replace the filter cartridges.

YES

Go to D

Contact your nearest Nederman representative for advice.

Has the airflow been satisfactory?

Is the fan operating correctly?

Does the impeller rotate in the right direction?

YES

Check the rotating direction of the fan impeller. Compare with the arrow on the label on the fan motor. It is very important that the rotation direction is right. If the impeller rotates in the wrong direction, the fan gives only 40 % of its possible air volume. Contact a qualified electrician if the impeller rotation must be reversed.

YES

Check if the system contains any dampers and the position of these. Open dampers to adjust the flow, but don’t exceed the dimensioned airflow for the filter unit.

Check that the filter 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 off the unit and clean the preseparator.

A valve is not operating correctly (but there are functioning valves).

Does the display on the control

box show Err + a digit?

YES

Go to B

Leaking compressed air system (notified by sound)

Are the external connections

leaking?

Is the air temperature below 0 °C ?

Check which valve is malfunctioning by listening. The 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.

YES

IMPORTANT! Turn off the compressed air supply with the service valve (accessory) before doing any work on the cleaning system.

If you have compressed air with a dew point close to or higher then the air temperature, the pilot valve may freeze. An indication is that the valve starts operating again when the temperature increases.

IMPORTANT! Do not pressurise the system if the temperature is below the minimum operating temperature

(= -20 °C). At lower air temperatures the process can be started and operated for a while (approx. 15 min.) whereafter the system can be pressurised.

YES

Repair the external connections.

High emission. Abnormal emission levels in the exhaust air.

Stop the system! Shut off the

compressed air and drain the tank.

Are all cartridges properly installed?

Install them properly.

YES

Stop the system. Decrease the system pressure to < 1 bar. Open the access door and find the leak.

Shut off the pressure and drain the tank.

Is a pulse-jet valve leaking ?

YES

Dismantle the valve and check for contamination or damaged parts. Clean and/or replace damaged parts.

Look into the cartridges and check if there are any traces of dust. Dust on the clean side indicates a leak. Replace damaged cartridges.

Replace other damaged parts.

SPARE PARTS

Ordering Instructions

When ordering spare parts always indicate the following. A. Part No. and Control No. (see FilterMax 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 cartridges (6-pack) 2 Circuit card (monitoring system) 3 Control box, complete

incl. electric components 4 Cover with display 5 Pulse valve

0 1

6 Pilot box, complete 7 Cleaning pipe (x 6) 8 Door gasket 9 Transformer 10 Pilot valve

10 6

REPLACEMENT CARTRIDGES (6-pack)

Basic PW

Dual layer polyester / polypropylen. Suitable for fumes and fine particles. Efficiency: 99 % at 0,5 µm Filter area: 10 m BIA class C Part no. 12372055

Poly Web

Spun bound polyester. Suitable for medium to coarse particles. Efficiency: 99 % at 0,5 µm Filter area: 10 m Washable BIA class C Part no. 12373279

Poly Web PTFE

PTFE membrane, laminated to spun bound polyester. Suitable for fine to medium particles. Efficiency: 99,9 % at 0,5 µm Filter area: 10 m Washable BIA class C Part no. 12372060

ACCESSORIES

INLET

With cleaning access panel on the top

Connection

diameter

Ø 250 mm Ø 315 mm Ø 400 mm Ø 500 mm

for FilterMax FI

Part no.

12372070 12372071 12372072 12372073

for FilterMax FO

Part no.

12373561 12373562 12373563 12373564

OUTLET

Connection

diameter

Ø 315 mm Ø 400 mm Ø 500 mm

for FilterMax FI

Part no.

12372057 12372058 12372059

for FilterMax FO

Part no.

12373565 12373566 12373567

DUST HANDLING SYSTEM

All container kits contains adapter and suitable extension legs if required.

FilterMax FI

Part no.

Container kit 2 x 40 l

Container kit 2 x 100 l, on wheels

Container, 40 l Container, 100 l

incl. lid

∆

P-CONTROL KIT

Is used for controlling the cleaning more efficiently and with better supervision. Saves pressured air in some applications with intermittent load. Equipped with alarm functions for high fall of pressure for filter. Part no. 12373603

12372140

12372067 12372228

12372655

FilterMax FO

Part no.

12373881

12373897 12373898

12373899

FILTER REGULATOR

Is used for setting the correct air pressure. Separates dust in the pressured air why it also protects the valves. Should be installed in the compressed air pipe line.

Must be positioned in a frost free environment Part no. 12372064

SHUT OFF VALVE FOR COMPRESSED AIR

An air venting type. Should be installed in the compressed air pipe line. Is used to turn off the compressed air supply before any service on the system is done.

Part no. 12372083

PRESSURE GAUGE KIT

Measures the pressure drop over the filter cartridges. Is mounted on the FilterMax’ stand. Part no. 12372079

1500

500 1500

2000

PRESSURE SWITCH FOR COMPRESSED AIR

Protects the filter from damage during use without compressed air. Must not be placed in explosion risk areas.

Part no. 12372142

PRESSURE SWITCH

(Not a Nederman product). Is used to indicate low airflow or high fall of pressure over the filter.

AFTER CLEANING DAMPER

(Not a Nederman product) The damper closes the duct when FilterMax F 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 F inlet.

SAFETY FILTER

Is recommended if the filtered air is recirculated into the facility. Please contact your Nederman dealer for more information.

INSTALLATION PROTOCOL, PAGE 1

If controls give results (for example measured values) which differ much from earlier results, this must be understood as a warning signal and lead to more careful investigations.

FilterMax F No.

Performed by

Control points

1. Delivery control (page 3) A. Missing components B. Transport damage

2. Installation control (page 4, 6 - 7) A. Safe mounting / foundation B. Fixing bolts / Traction forces C. Wind / Snow load D. Weight FilterMax F / collected dust E. Conductible screw fittings F. Inlet and Outlet G. Dust container or Dust feeder H. (2 or 3 filter units) J. Filter cartridges

Date

Result Result Result Note

3. Compressed air connection (page 8) A. Service valve B. Filter regulator C. Pressure switch D. Pressure 0,4 - 0,6 MPa E. Dew point F. Oil / Moisture G. Cleaning compressed air connections

4. Duct dimensioning (page 16) A. Duct diameters B. Inlet duct, length/inclination C. Cleaning access covers D. Fire damper E. After cleaning damper F. Flow meter G. NCF fan H. Extraction arms

INSTALLATION PROTOCOL, PAGE 2

FilterMax F No.

Performed by

Control points

5. Electrical installation (page 9-15) A. Overload protector B. Safety switch C. After cleaning damper D. Pilot box (1, 2 or 3) E. Fan F. Fan Starter

G. Extern START/STOP H. Pressure switch, compressed air J. Pressure switch, high dP/low airflow K. Fire alarm L. Dust feeder M. Sum alarm, alarm signal devices N. A-alarm O. Activating, in/outputs

Date

Result Result Result Note

6. Earth control measurement (page 12) A. GND1 - Inlet B. GND1 - Inlet cleaning access cover C. GND1 - Dust container

D. GND1 - Dust container adapter E. GND1 - Filter cartridges F. GND1 - Filter units

G. GND1 - Doors

7. Monitoring system, settings (page 18-19)

A. Cleaning during operation B. Pause time setting C. Cleaning after operation D. A-alarm function E. Remote control

8. System start A. Dimensioned airflow B. Actual airflow C. Filter ∆ P

SERVICE PROTOCOL (page 12, 23 - 25)

FilterMax F No.

Operating hours

Performed by

Control points

1. Dust container / Filter regulator A. Empty the dust container (when 70 % full) B. Water check filter regulator C. Water check pressure tank

2. Magnetic valves, function check

3. Remove dust, clean air room

every 2000 h *

every 1000 h *

4. Cleaning access covers, cleaning A. Check pre-separator inlet

5. Water check pressure tank

6. Checking the filter cartridges

Date

Result Result Result Result Result

every 6000 h *

A. Check cartridges for damage. B. Measure cartridge ∆ P. If higher that

1500 Pa replace the cartridges.

7. Remove corrosion by grinding, primer and touch up paint

8. Earth control measurement (page 12) A. GND1 - Inlet B. GND1 - Inlet cleaning access cover C. GND1 - Dust container D. GND1 - Dust container adapter E. GND1 - Filter cartridges F. GND1 - Filter units G. GND1 - Doors

9. Replacing the filter cartridges (page 25)

10. Check that the cables not are damaged or connected incorrectly

11. Airflow (adjust if neccesary) A. Dimensioned airflow B. Actual airflow

Every 1000 hours or at least once every 6th month. Every 2000 hours or at least once a year or when replacing filter cartridges. Every 6000 hours or at damage or insufficient filter function.

SERVICE PROTOCOL (page 12, 23 - 25)

FilterMax F No.

Operating hours

Performed by

Control points

1. Dust container / Filter regulator A. Empty the dust container (when 70 % full) B. Water check filter regulator C. Water check pressure tank

2. Magnetic valves, function check

3. Remove dust, clean air room

every 2000 h *

every 1000 h *

4. Cleaning access covers, cleaning A. Check pre-separator inlet

5. Water check pressure tank

6. Checking the filter cartridges

Date

Result Result Result Result Result

every 6000 h *

A. Check cartridges for damage. B. Measure cartridge ∆ P. If higher that

1500 Pa replace the cartridges.

7. Remove corrosion by grinding, primer and touch up paint

9. Replacing the filter cartridges (page 25)

10. Check that the cables not are damaged or connected incorrectly

11. Airflow (adjust if neccesary) A. Dimensioned airflow B. Actual airflow

Every 1000 hours or at least once every 6th month. Every 2000 hours or at least once a year or when replacing filter cartridges. Every 6000 hours or at damage or insufficient filter function.

SERVICE PROTOCOL (page 12, 23 - 25)

FilterMax F No.

Operating hours

Performed by

Control points

1. Dust container / Filter regulator A. Empty the dust container (when 70 % full) B. Water check filter regulator C. Water check pressure tank

2. Magnetic valves, function check

3. Remove dust, clean air room

every 2000 h *

every 1000 h *

4. Cleaning access covers, cleaning A. Check pre-separator inlet

5. Water check pressure tank

6. Checking the filter cartridges

Date

Result Result Result Result Result

every 6000 h *

A. Check cartridges for damage. B. Measure cartridge ∆ P. If higher that

1500 Pa replace the cartridges.

7. Remove corrosion by grinding, primer and touch up paint

9. Replacing the filter cartridges (page 25)

10. Check that the cables not are damaged or connected incorrectly

11. Airflow (adjust if neccesary) A. Dimensioned airflow B. Actual airflow

Every 1000 hours or at least once every 6th month. Every 2000 hours or at least once a year or when replacing filter cartridges. Every 6000 hours or at damage or insufficient filter function.

SERVICE PROTOCOL (page 12, 23 - 25)

FilterMax F No.

Operating hours

Performed by

Control points

1. Dust container / Filter regulator A. Empty the dust container (when 70 % full) B. Water check filter regulator C. Water check pressure tank

2. Magnetic valves, function check

3. Remove dust, clean air room

every 2000 h *

every 1000 h *

4. Cleaning access covers, cleaning A. Check pre-separator inlet

5. Water check pressure tank

6. Checking the filter cartridges

Date

Result Result Result Result Result

every 6000 h *

A. Check cartridges for damage. B. Measure cartridge ∆ P. If higher that

1500 Pa replace the cartridges.

7. Remove corrosion by grinding, primer and touch up paint

9. Replacing the filter cartridges (page 25)

10. Check that the cables not are damaged or connected incorrectly

11. Airflow (adjust if neccesary) A. Dimensioned airflow B. Actual airflow

Every 1000 hours or at least once every 6th month. Every 2000 hours or at least once a year or when replacing filter cartridges. Every 6000 hours or at damage or insufficient filter function.

SERVICE NOTES

Point no. Date Note

FilterMax F No.

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Nederman FilterMax F, FilterMax F 30, FilterMax F 90, FilterMax F 60 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual