FumeClean 230
Contents
1. UNITOR WELDING FumeClean 230 Portable high vacuum welding fume extractor Product no 196 735878 Instructions for use CONTENTS 1 IDENTIFICATION OF THE PRODUCT 2 SAFETY INSTRUCTIONS AND WARNINGS 3 USED PRODUCTS AND THE ENVIRONMENT 4 TECHNICAL SPECIFICATIONS 5 GENERAL DESCRIPTION 6 INSTALLATION 7 USE 8 MAINTENANCE 9 TROUBLESHOOTING 10 ORDERING AND SPARE PARTS Page 11 13 14 1 IDENTIFICATION OF THE PRODUCT The identification plate see fig 1 contains the following data serial number B product name max power speed setting high D supply voltage and frequency 2 SAFETY INSTRUCTIONS AND WARNINGS General The manufacturer does not accept any liability for damage to the product or personal injury caused by non observance of the safety instructions in this manual or by negligence during installation use maintenance and repair of the product mentioned on the cover of this document and any corresponding accessories Specific working conditions or used accessories may require additional safety instructions Immediately contact your supplier if you detect potential danger when using the product The user of the product is always fully responsible for observing the local safety instructions and regulations Observe all applicable safety instructions and regulations User manual e Everyone working on or with the product must be familiar with the contents of this ma2. the extraction capacity is sufficient When the extraction capacity decreases the filters should be replaced Decrease of extraction capacity may lead to a too high concentration of harmful welding fumes in the workshop When the machine is provided with a filter pollution indicator option there will be acoustic and optical signals when the extraction capacity is too low 10 8 MAINTENANGE The machine has been designed to function without problems for long time with minimum of maintenance In order to guarantee this some simple regular maintenance and cleaning activities are required which are described in this chapter If you observe the necessary caution and carry out the maintenance at regular intervals any problems occurring will be detected and corrected before they lead to a total standstill of the machine The indicated maintenance intervals can vary depending on the specific working and ambient conditions Therefore it is recommended to thoroughly inspect the complete machine once every year in addition to the indicated periodic maintenance Please contact your supplier for this inspection PHV I only Germany specific Inspection and maintenance in accordance with TRGS 560 W2 and W3 Inspection and maintenance of the product shall be carried out in conformance with TRGS 560 chapter 5 paragraph 9 A WARNING Overdue maintenance may cause a fire WARNING Always switch the machine OFF and remove the mains plug f
3. er use the product for extracting aggressive fumes such as hydrochloric acid The product may be used for extracting and or filtering fumes and gases that are released during the following welding processes e MIG MAG solid wire GMAW e MIG MAG flux cored wire FCAW e Stick welding MMA or SMAW e TIG GTAW welding Welding class W3 The product is suitable for the extraction of fume from metals that have a nickel and chrome for example content over 30 Never use the product for extracting and or filtering fumes and gases which are released during the following welding processes e MIG MAG welding robots with intensive use of TipDip or other anti spatter products e autogenic or plasma cutting e arc air gouging e welding with a release of a dense oil mist e paint spraying extraction of hot gases more than 40 C continuously e extraction of aggressive fumes Such as acids e grinding aluminium and magnesium e thermal spraying i e plasma etc e extraction of cement saw dust wood dust etc e sucking cigarettes cigars tissues and other burning particles objects and acids e any dangerous situations in which there is a risk of an explosion or fire A WARNING Never reach into the intake or outlet of the fan Modifications Modification of the product or any of its parts is not allowed 3 USED PRODUCTS AND THE ENVIRONMENT PACKAGING MATERIAL The purpose of the packaging is to protect the prod
4. g processes With its the wheels the handle and its compact design the machine is extremely suited to be used in relatively small workshops or near sources of pollution without a fixed location 5 2 Operation The machine works in accordance with the re circulation principle The extracted fumes pass the air intake and enter the pre separator in which primary filtration takes place and where sparks if any are separated Subsequently the air passes the pre filter and the main filter in which most of the fume particles are filtered out Finally the fan blows the air into the HEPA filter where the remaining fumes are separated The cleaned air is returned into the workshop via the outlet grid With the optional hose connection HCH 45 the air can be discharged elsewhere for example into the atmosphere such as is the case when welding stainless steel The welding fumes can be extracted at source in the following ways A by the supplied extraction hose 45 mm connected to the welding torch by the supplied extraction hose 45 mm connected to the extraction nozzle 6 INSTALLATION 6 1 Unpacking Check that the machine is complete The package should contain e portable welding fume extractor extraction hose 2 5 m 45 mm 4 carbon brushes user manual e electrical diagram 6 2 Installation The machine is ready for use A CAUTION Do not position the machine in places where it is exposed to vibrations or radiation fro
5. h integrated extraction Before use carefully read the user manual of the welding torch e Connect the extraction hose 45 mm at one side to the air intake of the machine and at the other side to the welding torch e Put the mass cable of the welding machine into the slit on top of the machine e Start up the machine by pressing the on off button Preferably use the automatic start stop device auto to extend the life of the carbon brushes e The machine continues to run for 15 seconds in the auto setting after welding is completed 7 2 2 PHV with extraction nozzle The machine can be supplied with two types of extraction nozzles funnel nozzle with magnetic foot EN 20 for various welding processes situations slit extraction nozzle with magnetic foot EN 40 for horizontal welding activities such as stick welding It is recommended that the extraction nozzle EN 20 is positioned above the welding spot when possible to achieve optimum welding fume extraction e Place the extraction nozzle at 2 4 cm from the source of pollution e Insert the mass cable of the welding machine into the slit on top of the extractor e Start up the machine by pressing the on off button Preferably use the automatic start stop device auto to extend the life of the carbon brushes e The machine continues to run for 15 seconds in the auto setting after welding is completed When using the machine regularly check that
6. m heat sources Observe the ambient conditions as described in chapter 4 4 6 3 Connection to the mains A CAUTION Make certain that the machine can be connected to the local mains Specifications with respect to supply voltage and frequency can be found on the identification plate 7 USE CAUTION Before use carefully read the safety regulations A WARNING It is required that the product is in an upright position and that the inlet is closed when transporting the product over larger distances 7 1 Controls The required under pressure will not be achieved in the low mode of operation As a consequence the warning signal will not be activated The control panel see fig 4 contains the following controls Button on off low high Button for switching the machine on and off and for switching from low to high motor speed and vice versa B Button manual auto Button for switching the machine from automatic on off to manual control and vice versa C Button reset optionally Button to reset the filter pollution indicator D Slit mass cable automatic start stop Slit for inserting the mass cable of the welding machine this activates the arc sensor for automatic on off switching of the extractor Min current 50 Amps E On off switch USA Canada Switch for switching the machine on and When this switch is installed button A s on off function becomes obsolete 7 2 Use 7 2 1 PHV with welding torc
7. mptied in the same bag e Loosen the side clips e Remove the top cover from the machine e Carefully remove the main filter C from the bottom of the machine e Check the seals before placing a new filter If the seals need to be replaced contact your supplier e Place the new filter and mount the disassembled parts in reverse order Check that the integrated aluminium pre filter is placed at the bottom 8 2 2 Replacement of the HEPA filter e Remove the outlet cover by loosening the two screws D e Remove the HEPA filter E e Place a new HEPA filter in the correct position open side at the top to facilitate this apply some suds to the seals e Remount the outlet cover by fastening the two screws Make sure that the outlet cover is in the right position the open side of the HEPA filter should correspond with the smallest opening of the outlet cover ATTENTION By taking out the HEPA filter its seals will deform For this reason never replace a used HEPA filter but always place a new one 12 9 TROUBLESHOOTING If the machine does not function correctly please consult the checklist below to see if you may remedy the error yourself If not please contact your supplier A WARNING Always switch OFF the machine and remove the mains plug from the wall socket before carrying out any repairs The repair activities in the table below indicated by 1 can be carried out by the user other activities shall onl
8. nual and must strictly observe the instructions therein Management should instruct their personnel in accordance with the manual and they must observe all instructions and directions given e Never change the order of the steps to perform e Always keep the manual with the product Intended use 1 The product has been designed exclusively for extracting harmful fumes and gases that are released during the most common light and medium welding processes Using the product for other purposes is considered contrary to its intended use The manufacturer accepts no liability for any damage or injury resulting from such use The product has been built in accordance with state of the art standards and recognized safety regulations Only use the product in technically perfect condition in accordance with its intended use and the instructions laid down in the user manual 1 Intended use as laid down in EN 292 1 is the use for which the technical product is suited as specified by the manufacturer inclusive of his directions in the sales brochure In case of doubt it is the use which can be deducted from the construction the model and the function of the technical product which is considered normal use Operating the machine within the limits of its intended use also involves observing the instructions in the user manual A WARNING Fire hazard Never use the product for extracting inflammable glowing or burning particles or solids or liquids Nev
9. rom the wall socket before carrying out the activities below First read the maintenance regulations at the beginning of this manual 8 1 Periodic maintenance The maintenance activities in the table below indicated by 1 can be carried out by the user other activities shall only be carried out by qualified personnel 8 2 Replacing the filters The main filter and the HEPA filter cannot be cleaned and therefore they have to be replaced periodically A WARNING A saturated filter often contains dust and dirt particles which could form a health hazard upon inhalation When replacing the filters always wear a high quality and approved face mask Wrap the filters in a properly closed plastic bag and dispose of it in compliance with the local regulations It is not allowed to empty the filters using air or by tapping Replace the filters in case of damage or when the extraction capacity has become insufficient due to the amount of pollution materials in the filter One must learn from experience when to replace the filters since the life of the filters strongly depends on the composition of the welding fumes the humidity etc Proceed as follows see fig 5 11 8 2 1 Replacement of the main filter Use the plastic bag that contains the new filter to exchange the filter for new one Draw the bag carefully over the old filter when removing the filter After that close the bag with a tie wrap The pre separator can also be e
10. uct during transport It consists of the following substances which can be reused polyethylene foil corrugated cardboard Do not dispose of the packaging material as industrial waste but ask your municipal sanitation department where to dispose of the material 4 TECHNICAL SPECIFICATIONS 4 1 General Net weight Extraction volume clean filter with 2 5 m hose and EN 20 e speed setting low 140 m3 h e speed setting high 230m3 h 99 9 incl HEPA filter H12 4 2 Dimensions 4 3 Electric system See the identification plate fig 1 and the separate electrical diagram Power consumption e speed setting low 70 e speed setting high 100 4 4 Ambient conditions Min operating temperature Max operating temperature Max relative humidity 50 4 5 Sound pressure The level of the A weighed sound pressure is 70 dB A according to ISO 3746 Measurements performed in the workshop with a PHV fitted with a welding torch 5 GENERAL DESCRIPTION The machine consists of the following main components see fig 3 control panel B fans mains cord D air intake 48 mm E bottom F pre separator G wheels H integrated prefilter main filter Dura H J outlet cover K HEPA filter L top cover 5 1 General description The machine has been specially designed for extracting and or filtering harmful fumes and gases that are released during the most common light and medium weldin
11. y be carried out by qualified personnel Always replace all motor seals when replacing or carrying out maintenance on the motors If the supply cord is damaged it must be replaced by the manufacturer or its service agents or a similarily qualified person in order to avoid hazard Problem Possible cause Solution Motor does not start Extraction capacity Main filter E i both main filter and HEPA insufficient filter 1 Extraction hose damaged or leak the extraction hose 1 Seals damaged or leaking Replace the seals Motor stops Thermal protection is activated Check that the cooling slits automatically underneath the top cover and or the outlet are not obstructed Dust or smoke coming Filter torn or placed incorrectly Replace the filter or position it out of the outlet grid correctly 1 13 10 ORDERING AND SPARE PARTS FumeClean 230 Product number 196 735878 Delivered complete with 2 5m hose and nozzle with magnet foot Optionals Bulkhead bracket 196 740399 Hose connection outlet side 196 740381 Active carbon filter 196 740431 14 Unitor ASA Mail P O Box 300 Sk yen N 0213 Oslo Norway Office Drammensvn 175 N 0277 Oslo Norway Tel 47 22 13 14 15 Fax 47 22 13 45 00 76004 UNITOR N www unitor com 15
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