Extor 4100R5 Operation/Maintenance And Installation

OPERATION, MAINTENANCE, AND

INSTALLATION

EXTOR 4100R5

Page 2 / 37

TABLE OF CONTENTS

TABLE OF CONTENTS ......................................................................................................................................... 2

BASIC INFORMATION ......................................................................................................................................... 3

EU - DECLARATION OF CONFORMITY ................................................................................................................ 5

SAFETY INSTRUCTIONS ...................................................................................................................................... 6

TECHNICAL SPECIFICATIONS .............................................................................................................................. 7

DESCRIPTION OF FUNCTIONALITY ..................................................................................................................... 9

EXTOR VACUUM-BLOWING SYSTEM ............................................................................................................... 10

ACCEPTANCE INSPECTION ............................................................................................................................... 11

DIMENSIONS .................................................................................................................................................... 12

INSTALLATION.................................................................................................................................................. 13

ASSEMBLY ........................................................................................................................................................ 14

INSTALLATION OF THE FILTERS ........................................................................................................................ 15

ALIGNMENT OF THE BLOWING OUTLET .......................................................................................................... 16

PRESSURIZED AIR CONNECTION ...................................................................................................................... 17

ELECTRICAL CONNECTION ............................................................................................................................... 18

STARTING AND STOPPING THE EQUIPMENT ................................................................................................... 19

SYSTEM CONTROL SETTINGS ........................................................................................................................... 20

EXTERNAL CONNECTIONS................................................................................................................................ 23

A. EMPTYING THE COLLECTING BIN (WITH A CLOSING FLAP) ..................................................................... 24

B. OPERATION WITH A DROP-THROUGH ROTARY FEEDER (OPTIONAL) ..................................................... 25

MANUAL CLEANING (ACCESSORY) .................................................................................................................. 26

MAINTENANCE INSTRUCTIONS ....................................................................................................................... 27

REPLACEMENT OF MAIN FILTERS .................................................................................................................... 29

REPLACEMENT OF CONTROL FILTERS .............................................................................................................. 31

STORAGING...................................................................................................................................................... 32

TROUBLESHOOTING ........................................................................................................................................ 33

INSTRUCTIONS FOR RECYCLING AND DISPOSAL OF EXTOR VACUUM UNITS ................................................. 35

ACCESSORIES ................................................................................................................................................... 36

INSPECTION LIST .............................................................................................................................................. 37

WIRING DIAGRAMS

DOCUMENTS

Page 3 / 37

BASIC INFORMATION

IMPORTANT

Read this instruction manual carefully before you install, operate, or

service the EXTOR 4100 suction equipment.

This manual is part of the delivered product and should be stored

throughout the whole lifespan of the product. All amendments should be

appended to this manual. These instructions should be handed over to the

possible new user.

Follow the instructions of this manual. You can ensure that the equipment

functions properly by following the operation and maintenance

instructions.

This product has been designed and manufactured to comply with

the appropriate requirements of EU directives. In order to retain this

level of quality, competent personnel and original spare parts must

be used during installation, repairs, and maintenance. Extor Oy, the

manufacturer, gives technical assistance and supplies spare parts.

DOCUMENT DATA

Identification code: KH-4100r5______ Revision No. 01_______

Completion date: 2013-08-14______

Revision date: 2014-03-25______

Page 4 / 37

VACUUM UNIT DATA

Type

Extor 4100 R5______

Identification number

____________

In your communication with the producer please state the above

information.

BLOWER DATA

Frequency [Hz]

50

50/60

Overall efficiency [%]

77.6

68.7/68.0

Coupling method C – a channel is connected to the suction inlet of the

blower and the blower operates freely

Efficiency category

Static

Efficiency grade

76 70/70

Year of manufacture

2014

Manufacturer

Extor Oy

Business ID

1893921-9

Place of manufacture

Kotka, Finland

Model number

E10195-1

E10060-1

Frequency [Hz]

50

50/60

Motor input power [kW]

3.8

2.8/4.8

Flow rate [m/s]

15.0

13.0/15.4

Vacuum [Pa]

3080

2360/3300

Motor speed [rpm]

2870

2870/3440

Specific ratio

1.03

1.02/1.03

Page 5 / 37

EU - DECLARATION OF CONFORMITY

Manufacturer:

Extor Oy

Contact details of manufacturer:

P.O.BOX 11

FIN-48201 KOTKA

Takojantie 14

FIN-48220 KOTKA

FINLAND

Tel. +358 5 229 6900

Fax +358 5 212 066

E-mail: [email protected]

www.extor.fi

Device type:

Extor 4100 R5

Identification number:

______

We declare that the suction unit Extor 4100

 comply directive (2006/42/EC) on machinery and its enactment of national directive

requirements

 SFS-EN ISO 12100

 comply low voltage directive (2006/95/EY)

 SFS-EN 60439-1 + A1:2005, SFS-EN 60439-3 + A1 + A2:2001, EN 60204-1

 comply EMC‐ directive (2004/108/EY)

 EN 61000-6-1:2007, EN 61000-6-2:2005, EN 61000-6-3:2007, EN 61000-6-4:2007

 fulfils the Ecodesign Directive (2009/125/EU) and Commission regulation 327/2011

(EU) issued on the basis of the directive, concerning the ecological design of blowers

 SFS-EN ISO 5801

The device bears the CE-marking since 2014

__ Kotka, Finland Timo Valkama, CEO

Page 6 / 37

SAFETY INSTRUCTIONS

 Use only original spare parts.

 Do not wash the equipment with water.

 Do not operate the device without filters.

 Do not use the device for the removal of fumes.

 Disconnect the device from the mains before starting with maintenance works.

 Discharge pressure from the compressed air lines of the equipment before starting with

maintenance works.

 Engage the safety lock before starting with maintenance and repair works. The person

conducting the maintenance work should hold the key of the safety lock.

 Use safety goggles, a respirator and safety gloves when servicing, operating or repairing

the equipment.

 Do not vacuum water or any other liquid.

 Do not vacuum sharp materials such as metal or glass, which could damage the filters.

 Do not vacuum smoldering or burning materials.

 Use the fire extinguishing equipment intended for electrical devices in case of fire.

IMPORTANT!

This device is designed for the removal and filtration of NON-EXPLOSIVE dry dust.

Use the device only for the applications described in this manual.

Follow the maintenance and safety instructions of this manual to ensure efficient and safe

operation of the device.

Page 7 / 37

TECHNICAL SPECIFICATIONS

Frequenzy [Hz]

50

50/60

Air volume [m

3

/h]

4800

4100/4800

Vacuum [Pa]

4800

3600/4800

Voltage [V]

400

Current [A]

12,3

6,9/12,3

Power [kW]

5,5

Noise level [dB]

75

70/75

Pressurized air [bar]

4 - 5

Consumption of pressurized air [l/m]

80 - 120

Pressurized air connection [mm]

8MM

Cleaning of filters

pneumatic

Voltage [V]

24

Main filters [m

2

]

filtering material

3 x 15

PTFE

EN 1822 class

E11

filtration level (MPPS)

> 95 %

Control filter [m

2

]

filtering material

16

micro

EN 1822 class

E11

filtration level (MPPS)

> 95 %

IP class

IP54

Weight [kg]

280

(368) With drop-through rotary

feeder

Page 8 / 37

0

1000

2000

3000

4000

5000

6000

0 1000 2000 3000 4000 5000 6000

Air volume [m3/h]

Vacuum [Pa]

60 HZ

50 HZ

60 HZ

0

1000

2000

3000

4000

5000

6000

0 1000 2000 3000 4000 5000 6000

Air volume [m3/h]

Vacuum [Pa]

50 HZ

Page 9 / 37

DESCRIPTION OF FUNCTIONALITY

Suodatinpatruunat puhdistetaan

yksitellen. Suodattimesta suljetaan

imu ja johdetaan ilmaimpulssi

suodattimen sisään.

A drop-through rotary

feeder (option)

continuously discharges

while the suction

equipment is running.

Close off suction from the filter

you want to clean, and then shoot

a pressure impulse into the filter.

The pressure impulse removes

any dust that has accumulated on

the filter surface.

The suction air is guided

into the filter unit

tangentially.

The clean air can be used

for suction blowing, which

makes the dust removal

significantly more effective.

Some of the clean air is guided

through the control filter back into

the room air.

After the collecting bin is

full, the closing flap is

closed, and the collecting

bin can be emptied while

the suction equipment is

running (option).

Dust particles move on the

rim of the filter unit flange,

and about 80% of the dust

goes directly into the

collecting bin.

You can connect a hose to

the cleaning inlet for

manual vacuuming

(option).

Page 10 / 37

EXTOR VACUUM-BLOWING SYSTEM

Dust extraction efficiency can be increased by guiding MAX. 50% of filtered air back to the

target room.

For proper functioning of the vacuum-blowing system it is important to maintain sufficient

underpressure in the cleaned room. When using the system, an adjusting damper adjusts the

proper vacuum and blowing ratio for each individual case.

50 %

100 %

50 %

Adjusting damper

Direction

adjusted grills

Page 11 / 37

Part * = ACCESSORY

A. Seal (collecting bin, 50 l)*

B. Suction unit cover

C. Motor section 5,5kW 50hz

5,5kW 50/60 hz

D. Control filter

E. Pneumatic closing flap 250

F. Filter cleaning unit

G. Filter PTFE

H. Service door

I. Collecting bin 50 l

J. Control centre

K. Suction hose d60 L=10 m*

L. Pneumatic terminal

M. Pressure gauge

N. Pneumatic filter.

O. Overfilling sensor*

P. Drop-through rotary feeder

Q. Set of cables (remote control)

ACCEPTANCE INSPECTION

B

D

C

F

G

H

I

O

J

N

M

L

A

E

P

K

 Inspect the device for any transport damage.

 Check to ensure that all parts have been

delivered.

 Contact the supplier of the device, if any parts are

missing or damaged.

 The packaging materials (i.e., the wood,

cardboard, and plastic, as well as the binding

belts) are non‐toxic and can be burnt safely.

Page 12 / 37

DIMENSIONS

 When performing the installation,

remember the minimum space required for

installation, maintenance and operation.

 The minimum space to be left around the

equipment should conform to the

rectangular area in the Figure on the left.

Page 13 / 37

When installing the vacuum equipment, pay attention to the following:

 Ensure that the foundation is even.

 The total weight of the equipment.

 Centre of gravity of the equipment.

 Any wind load.

 Installation on a concrete base or a similar sufficiently solid base.

 There must be at least 500 mm of free space above the suction unit.

 Ambient temperature 0 - 40 °C non-condensing

The equipment is designed for indoor installation. Please contact the manufacturer if you are

planning to install the equipment elsewhere.

INSTALLATION

Without the footing, the

centre of gravity is

located high in the fan

section.

Page 14 / 37

x 4

5. Connect the

pneumatic plug.

3. Usually the suction

unit is fastened to the

concrete floor with

expansion bolts. If

necessary, use

adjustment blocks to

ensure levelness of the

suction unit.

2. Install the upper

section to the

stand. Make sure

that the alignment

is correct.

1. Attach slings to the

four eyes. Ensure

uniform load

distribution.

4. Route cables to

cable clamps.

x 12

WARNING

Do not stand under a suspended load.

Use only approved lifting gear for lifting, assembling and transferring

the equipment. Otherwise there is a risk of severe injuries or death.

ASSEMBLY

6. Connect the

power plug of the

motor.

Page 15 / 37

INSTALLATION OF THE FILTERS

11

IMPORTANT!

Remember to lubricate the

door gaskets with the

silicone stick supplied,

before installation.

1. Remove locks (2 pcs) and open the

latches (6 pcs).

2. Remove the service door.

3. Take the new filter and place

the loop located at the top of

the filter into the holder.

4. Install the filter and tighten the

bolt.

5. Check that the filters are properly

in their seats.

6. Close the maintenance door by

locking simultaneously the

opposite latches. Install the

locking elements.

Page 16 / 37

360°

1. Open the locking latches (4 pcs).

2. Turn the outlet in the desired

direction.

3. Lock the latches.

ALIGNMENT OF THE BLOWING OUTLET

Make sure that the gasket is in its

place

x4

Page 17 / 37

Pressurized air connection

IMPORTANT!

 The pressure in the pressurized air

network must be between 0,4 and

0,5 MPa (4 - 5 Bar, 58 - 72 psi).

 Do not install the water separator in a

room, where temperature may fall

below 0 °C.

 Use dry oilfree compressed air.

 Pressurized air that is unclean or has

inferior pressure can weaken the

efficiency of the cleaning system.

Water separator

Compressed air supply is shut off from a line leading to the compressed air connection of the

equipment. Compressed air lines of the equipment are discharged from the bottom of the

water separator.

PRESSURIZED AIR CONNECTION

Page 18 / 37

5x32 A 400V

IMPORTANT!

Check the arrow mark on the motor to verify that the motor is rotating in the right

direction.When the rotation direction of the motor is incorrect, the suction capacity is more

than 50 % lower. Contact a professional electrician, if it is necessary to change the rotation

direction.

ELECTRICAL CONNECTION

WARNING

Risk of electric shock!

- Disconnect the device from mains supply

before carrying out maintenance work.

- Electrical works may only be carried out

by a competent person authorised for

the work.

- Use the safety lock. The person

performing maintenance works should

hold the key of the safety lock.

Page 19 / 37

STARTING AND STOPPING THE EQUIPMENT

1. Turn the main switch to 0 position.

2. Pressurise the compressed air system of

the vacuum equipment.

3. Connect the electrical plug.

4. Turn the main switch to position 1.

5. The display panel will now display the

main menu.

6.

F1=START

F2=STOP

F3=REMOTE

F4=SETTINGS

If you want to bypass cleaning after

use, press 'F4' after you have

stopped the suction machine.

Press "F2", which

shuts off the suction,

and cleaning begins

after operation.

Press 'F1', and the

suction machine will

start.

Page 20 / 37

SYSTEM CONTROL SETTINGS

OVERFILL OF THE COLLECTING TANK

The extraction system turns off when the overfill sensor of the collecting tank has been

triggered for a specified period. The time limit can be changed on the display panel. A time limit

of one hour has been pre-defined by the factory.

WARNING! After switching off the system, it performs cleaning the filter

after operation. Do not open the service door during the cleaning

process!

MESSAGES ON THE DISPLAY OF THE CONTROL PANEL

During operation, the operating time, the actual pressure difference across the filter and the

pressure difference and the clearing limits are shown on the display. In addition, an error

message may also appear.

The following alarm messages are displayed on the panel display:

 Phase monitoring: ’PHASE AND SEQUENCE LOSS’

 Safety switch switched on: ’SAFETY SWITCH’

 Heat relay of the motor: ’THERMAL RELAY’

 The overfill sensor indicates that the collecting bin is full: ’EMPTY THE COLLECTING BIN

> PRESS F4 4S’

 Recommended maintenance interval exceeded: ’INSPECTION PUSH F4 10S WHEN

SERVICE HAVE DONE’

Acknowledge the alarm messages displayed on the control panel with the "F4" key.

Run 00h00m

400 Now

3000 On

2000 Off

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Extor 4100R5 Operation/Maintenance And Installation

Extor 4100R5 Operation/Maintenance And Installation

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