Aerservice Equipments OTS User manual

OTS

SUNTO

User manual

Instructions for

use and

maintenance

©| Aerservice Equipments S.r.l.

Reproduction of this manual, total or partial, is forbidden

 
 
 
Instruction manual for use and maintenance - EN 
 
Rev.: 0 –aggiornato al 06/11/2020 
| Con riserva di modifiche tecniche e salvo errori | 
Pag. 1di 39 
 
Index 
GENERAL INFORMATION........................................................................................................................... 3 
1. Introduction....................................................................................................................................... 3 
2. Information on copyright and related rights..................................................................................... 3 
3. Instructions for the user.................................................................................................................... 3 
SAFETY ....................................................................................................................................................... 4 
1. General information.......................................................................................................................... 4 
2. Warnings and symbols in the user manual ....................................................................................... 4 
3. Signs applied by the user................................................................................................................... 4 
4. Safety warnings for the operator ...................................................................................................... 5 
5. Safety warnings for maintenance and troubleshooting.................................................................... 5 
6. Warning about specific dangers........................................................................................................ 6 
UNIT DESCRIPTION .................................................................................................................................... 7 
1. Purpose.............................................................................................................................................. 7 
2. Features and versions........................................................................................................................ 8 
3. Proper use ......................................................................................................................................... 8 
4. Improper use of the unit ................................................................................................................... 9 
5. Marks and labels on the unit............................................................................................................. 9 
6. Residual risk..................................................................................................................................... 10 
TRANSPORT AND STORAGE..................................................................................................................... 10 
1. Transport ......................................................................................................................................... 10 
2. Storage............................................................................................................................................. 10 
ASSEMBLY................................................................................................................................................ 11 
1. Unpacking and castors assembling.................................................................................................. 11 
2. Flexible hose assembly .................................................................................................................... 12 
USE........................................................................................................................................................... 12 
1. User qualification............................................................................................................................. 12 
2. Control panel................................................................................................................................... 13 
3. Correct use of the fume torch......................................................................................................... 14 
4. Electric connection .......................................................................................................................... 15 
5. Start of the unit ............................................................................................................................... 15 
6. Automatic Start-Stop....................................................................................................................... 15 
REGULAR MAINTENANCE ........................................................................................................................ 17 
1. Care.................................................................................................................................................. 17 
2. Ordinary maintenance..................................................................................................................... 18 
3. Replacement of filters ..................................................................................................................... 18 
4. Digital control panel: alarms and alarm reset................................................................................. 20 

Instruction manual for use and maintenance - EN

Rev.: 0 –aggiornato al 06/11/2020

| Con riserva di modifiche tecniche e salvo errori |

Pag. 2di 39

7.5. Troubleshooting .............................................................................................................................. 22

7.6. Emergency measures....................................................................................................................... 22

8. DISPOSAL ................................................................................................................................................. 23

8.1. Plastics............................................................................................................................................. 23

8.2. Metals.............................................................................................................................................. 23

8.3. Filtering media................................................................................................................................. 23

9. ATTACHMENTS ........................................................................................................................................ 24

9.1. OTS 1torch Technical data.............................................................................................................. 24

9.2. OTS 1torch / inverter Technical data............................................................................................... 25

9.3. OTS 2torches Technical data .......................................................................................................... 26

9.4. OTS 2torches / inverter Technical data........................................................................................... 27

9.5. Spare parts and accessories ............................................................................................................ 28

9.6. EC declaration of conformity........................................................................................................... 29

9.7. UK Declaration of Conformity (UKCA)............................................................................................. 30

9.8. Dimensional drawing....................................................................................................................... 31

9.9. Wiring diagram OTS 1t..................................................................................................................... 32

9.10. Wiring diagram OTS 1t + inverter................................................................................................ 32

9.11. Wiring diagram OTS 2t –400V..................................................................................................... 33

9.12. Wiring diagram OTS 2t –110V..................................................................................................... 33

9.13. Wiring diagram OTS 2t + inverter –400V.................................................................................... 34

9.14. Schema elettrico OTS 2t + inverter –230V ................................................................................. 34

9.15. Inverter technical data ................................................................................................................ 35

9.16. Air connection ............................................................................................................................. 37

Instruction manual for use and maintenance - EN

Rev.: 0 –aggiornato al 06/11/2020

| Con riserva di modifiche tecniche e salvo errori |

Pag. 3di 39

1. GENERAL INFORMATION

1.1. Introduction

This user manual provides important information for the correct and safe operation of Aerservice

Equipments’ mobile filter unit OTS suitable for extraction of welding fumes.

The instructions contained in this manual help to avoid dangers, to reduce repair costs and machine

downtime and to increase the reliability and lifetime of the unit.

The user manual shall always be at hand; all information and warnings contained therein shall be read,

observed and followed by all people who work by the unit and are involved in tasks, such as:

-transport and assembly;

-normal use of the unit during work;

-maintenance (replacement of filters, troubleshooting);

-disposal of the unit and its components.

1.2. Information on copyright and related rights

All information included in this instruction manual must be treated confidentially and may be made

available and accessible only to authorized people.

It may be disclosed to third parties only with the prior written consent of Aerservice Equipments.

All documentation is protected under the copyright law.

Any distribution or reproduction, in total or partial, of this document, as well as its use or transmission

without prior and explicit authorization by Aerservice Equipments, is prohibited.

Any violation of this prohibition is punishable by law and involves penalties.

All rights relating to industrial property rights are reserved to Aerservice Equipments.

1.3. Instructions for the user

These Instructions are an integral part of the unit OTS.

The user must ensure that all personnel in charge of the unit have adequate knowledge of these

Instructions.

The user is required to complete the Manual with instructions based on national regulations for injury

prevention and environmental protection, including information on surveillance and notification

obligations, in order to consider specific requirements, such as organization of work, working methods

and personnel involved.

In addition to the instructions and regulations for the prevention of accidents, in force in the country

and in the place where the unit is used, it is necessary to comply with the common technical principles

for a safe and correct use of the unit.

The user shall not make any modifications to the unit, nor add parts or adjust it without permission by

Aerservice Equipments because this could jeopardize its safety!

The spare parts used shall correspond to the technical specs established by Aerservice Equipments.

Always use original spare parts to ensure correspondence of the unit to the technical specifications.

Allow only trained and expert personnel for the operation, maintenance, repair and transport of the

unit.

Establish individual responsibilities for operation, configuration, maintenance and repair.

Instruction manual for use and maintenance - EN

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| Con riserva di modifiche tecniche e salvo errori |

Pag. 4di 39

2. SAFETY

2.1. General information

The unit was developed and manufactured using the latest technology and in accordance with the

general workplace safety guidelines.

However, the use of the unit could present risks for the operator or risks of damage to the unit and other

objects:

-If the personnel in charge has not received instructions or training;

-In case of use that is not in accordance with the intended purpose;

-In case of maintenance that is not carried out as indicated in this manual.

2.2. Warnings and symbols in the user manual

This warning indicates an imminent dangerous situation.

Not respecting it can result in death or serious injury.

This warning indicates a possible dangerous situation.

Not respecting it can result in death or serious injury.

This warning indicates a possible dangerous situation.

Not respecting it can result in minor injury or material damage.

This warning provides useful information for safe and proper use.

•The point in bold marks the work and / or operating procedure.

The procedures need be performed in sequence.

-Any list is marked with a horizontal dash.

2.3. Signs applied by the user

The user is responsible for the application of signs on the unit or in the near area.

Such signs may concern, for example, the obligation to wear personal protective equipment (PPE).

Refer to the local regulations for advice.

DANGER

WARNING

INFO

Instruction manual for use and maintenance - EN

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| Con riserva di modifiche tecniche e salvo errori |

Pag. 5di 39

2.4. Safety warnings for the operator

Before using the unit, the operator in charge must be suitably informed and trained for the use of the

unit and the relevant materials and means.

The unit must only be used in perfect technical condition and in compliance with the intended purposes,

the safety standards and the warnings relating to dangers as reported in this Manual.

All failures, especially those that can jeopardize safety, shall be removed immediately!

Each person responsible for commissioning, use or maintenance of the unit must be familiar with these

instructions and must have understood their content, especially paragraph 2 Safety.

It is not enough to read the manual for the first time when you are already working.

This is especially true for people who work on the unit only occasionally.

The manual shall always be available near the unit.

No liability is accepted for damage or injury due to failure to comply with these instructions.

Observe the current workplace precaution rules, as well as other general and standard technical safety

and hygiene tips.

Individual responsibilities for the various maintenance and repair operations must be clearly established

and respected. Only in this way malfunctions can be avoided - especially in dangerous situations.

The user shall ensure that the personnel responsible for use and maintenance of the unit shall wear

personal protective equipment (PPE). These are mainly safety shoes, goggles and protective gloves.

Operators must not wear long loose hair, baggy clothing or jewelry! There is a risk of being trapped or

drawn in by the moving parts of the unit!

In case of any changes on the unit, that may affect safety, switch off the equipment immediately, secure

it and report the incident to the department / person in charge!

Interventions on the unit can only be carried out by competent, reliable and trained personnel.

Personnel undergoing training or in a training program may only be permitted to work on the unit under

the constant supervision of a trained person.

2.5. Safety warnings for maintenance and troubleshooting

For all maintenance and troubleshooting, ensure to use suitable personal protective equipment.

Before proceeding with any maintenance work, clean the unit.

An industrial vacuum cleaner with H efficiency class for dust can be helpful.

The preparation, maintenance and repair operations, as well as the detection of faults can only be

carried out if the unit is without power supply:

•Remove the plug from the mains supply.

All screws that were loosened during maintenance and repair work need always be fastened again!

If so foreseen, the screws must be tightened with a torque wrench.

Before proceeding with maintenance and repairs it is necessary to remove all impurities, especially on

the parts fastened with screws.

Instruction manual for use and maintenance - EN

Rev.: 0 –aggiornato al 06/11/2020

| Con riserva di modifiche tecniche e salvo errori |

Pag. 6di 39

2.6. Warning about specific dangers

All work on the electrical device of the unit shall be carried out exclusively by a qualified

electrician or by personnel with the necessary training, under the direction and supervision

of a qualified electrician and in accordance with the relevant safety standards.

Before any activity on the unit, it is necessary to disconnect the electric plug from the mains

supply, to prevent accidental restarting.

Use only original fuses with the prescribed current limit.

All electrical components to be inspected, maintained and repaired must be disconnected.

Block the devices used to disconnect the voltage, in order to avoid accidental or automatic

restart.

First check the absence of voltage on the electric components, then isolate the adjacent

components. During repairs, be careful not to modify the factory parameters so as not to

jeopardize safety.

Check the cables regularly and replace in case of damage.

Skin contact with welding powders etc. can cause irritation to sensitive people.

Repair and maintenance of the unit must only be carried out by qualified and authorized

personnel, in compliance with safety requirements and accident prevention regulations in

force.

Danger of serious damages to respiratory system.

To prevent contact with dust and inhalation, use protective clothing and gloves and an

assisted ventilation device to protect the respiratory tissue.

During repairs and maintenance interventions, avoid diffusion of dangerous dust, in order

to prevent health damage even of people not directly affected.

The unit can produce noise emissions, specified in detail in the technical data.

If used with other machinery or due to the characteristics of the place of use, the unit may

generate a higher sound level.

In this case, the person in charge is required to provide the operators with adequate

protective equipment.

DANGER

WARNING

Instruction manual for use and maintenance - EN

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| Con riserva di modifiche tecniche e salvo errori |

Pag. 7di 39

3. UNIT DESCRIPTION

3.1. Purpose

The unit is a compact mobile device suitable for filtration of welding fumes extracted directly at source,

with a high separation rate according to the specific application.

The unit can be equipped with one or two flexible hoses to fume torches (the flexible hose, the fume

torch and the quick coupling are not included in the unit).

The fumes (rich in polluting particulate) are purified through a multi-stage filtering section, before being

released back in the workplace.

Pos.

Description

Pos.

Description

Control panel

Filter inspection door lock

Air flow regulator

Flexible hose connection

On-Off switch

Swivel wheels with brake

Panel socket

Rear wheels

Inverter access door

Compressed air inlet

Mass cable clamp

Handles

Clean air expulsion grid

Instruction manual for use and maintenance - EN

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| Con riserva di modifiche tecniche e salvo errori |

Pag. 8di 39

3.2. Features and versions

The mobile air cleaner is available in five versions:

-OTS 1t

with cartridge filter - mechanical filtration

higher filter efficiency: ≥99% | M (sec. DIN 660335-2-69)

-OTS 1t / inverter

with cartridge filter - mechanical filtration

higher filter efficiency: ≥99% | M (sec. DIN 660335-2-69)

air flow regulation by inverter

-OTS 2t

with cartridge filter - mechanical filtration

higher filter efficiency: ≥99% | M (sec. DIN 660335-2-69)

-OTS 2t / inverter

with cartridge filter - mechanical filtration

higher filter efficiency: ≥99% | M (sec. DIN 660335-2-69)

air flow regulation by inverter

-OTS 2t / triac (only 110V)

with cartridge filter - mechanical filtration

higher filter efficiency: ≥99% | M (sec. DIN 660335-2-69)

air flow regulation by triac

3.3. Proper use

The unit has been conceived to extract and filter the welding fumes generated by industrial welding

processes, directly at source. In principle, the unit can be used in all work processes with emission of

welding fumes. However, it is necessary to prevent the unit from sucking in "spark showers" from

grinding or similar.

Pay attention to the dimensions and further data that are mentioned in the technical data sheet.

Carefully read and comply with the instructions in chapter “9.1 Technical data of the unit”.

The use in accordance with the instructions of this manual also means following the specific

instructions:

-for safety;

-for use and setting;

-for maintenance and repair,

mentioned in this user manual.

Any further or different use is to be considered as non-compliant.

The user of the unit is the sole responsible for any damage resulting from such non-

compliant use.

This also applies to arbitrary interventions and unauthorized modifications on the unit.

INFO

Instruction manual for use and maintenance - EN

Rev.: 0 –aggiornato al 06/11/2020

| Con riserva di modifiche tecniche e salvo errori |

Pag. 9di 39

3.4. Improper use of the unit

The unit is not suitable for use in hazardous areas falling under ATEX regulation.

Furthermore, the equipment should not be used in the following cases:

-Applications not corresponding to the intended purpose or not indicated for proper use of the unit

and in which the air to be extracted:

•contains sparks, for example from grinding, of a size and quantity such as to damage the suction

arm and set fire to the filtering section;

•contains liquids that may contaminate the air flow with vapors, aerosols and oils;

•contains easily flammable dusts and / or substances that may cause explosive mixtures or

atmospheres;

•contains other aggressive or abrasive powders that may damage the unit and its filters;

•contains organic and toxic substances / components (VOCs) which are released during the

separation process. Only by inserting the active carbons filter (optional) the unit becomes

suitable for filtration of these substances.

-The unit is in an outdoor area, where it is exposed to atmospheric agents: the unit must be installed

exclusively in closed and / or repaired buildings. Only a special version of the unit (with specific

indications for outdoors) can be installed outside.

Any waste, such as for example collected particles, may contain harmful substances, therefore they must

not be delivered to landfills for municipal waste. It is necessary to provide for an ecological disposal

according to local regulations.

If the unit is used in accordance with its intended purpose, there is no reasonably foreseeable risk of

improper use that might endanger health and safety of personnel.

3.5. Marks and labels on the unit

The unit has marks and labels which, if damaged or removed, need be immediately replaced with new

ones in the same position.

The user may have the obligation to place other marks and labels on the unit and in the surrounding

area, e.g. referring to the local regulations for the use of personal protective equipment (PPE).

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