PLYMOVENT 0507345000 Portable Welding Fume Extractor User Manual

PLYMOVENT 0507345000 Portable Welding Fume Extractor

Product Information

• Model: PHV
• Manufacturer: www.plymovent.com

Product Usage Instructions

Safety Precautions and Warnings
The user is responsible for complying with local safety regulations and guidelines at all times. Follow all applicable safety precautions and guidelines.

Intended Use
The product is designed for extracting smoke and substances released during common light to medium welding processes. Any other use is not by its intended purpose. The manufacturer does not accept liability for any damage or injury resulting from such use. Only use the product in technically perfect condition as described in the manual.

Special Note:
When extracting welding fumes containing carcinogenic substances like nickel or chromium, follow the requirements of TRGS 560 for recirculation.

Warnings

• Fire Hazard Warning: Do not use the product to extract flammable, glowing, or burning particles and liquids. Avoid using it for aggressive fumes like hydrochloric acid.
• Welding Fume Class W3: Suitable for extracting fumes from metal with an alloy content of nickel and chromium above 30%.
• Caution: Never put your hand(s) into the fan’s inlet and outlet openings.

Frequently Asked Questions

• Q: What is the primary use of the PHV model?
  A: The PHV model is specifically designed for extracting welding smoke and substances produced during light to medium welding processes.

• Q: Can the PHV model be used for extracting all types of fumes?
  A: No, the PHV model should not be used for extracting flammable, glowing, or burning particles and liquids, as well as aggressive fumes like hydrochloric acid.

• Q: How should I handle welding fumes containing carcinogenic substances?
  A: When dealing with welding fumes containing carcinogenic substances like nickel or chromium, ensure compliance with the requirements of TRGS 560 for recirculation.

All rights reserved.

• No part of this publication may be copied or published through printing, photocopying, microfilm, or otherwise without prior written consent of the manufacturer. This restriction also applies to the corresponding drawings and diagrams.
• The information given in this document has been collected for the general convenience of our clients. It has been based on general data on construction material properties and working methods known to us at the time of issue of the document and is therefore subject at any time to change or amendment and the right to change or amend is hereby expressly reserved. The instructions in this publication only serve as a guideline for the installation, use, maintenance, and repair of the product mentioned on the cover page of this document.
• This publication is to be used for the standard model of the product of the type given on the cover page. Thus the manufacturer cannot be held responsible for any damage resulting from the application of this publication to the version delivered to you.
• This publication has been written with great care. However, the manufacturer cannot be held responsible, either for any errors occurring in this publication or for their consequences.
• TAKE YOUR TIME TO CAREFULLY READ AND UNDERSTAND THE MANUAL BEFORE USING THE PRODUCT. ALWAYS KEEP THE MANUAL WITH THE PRODUCT.

IDENTIFICATION OF THE PRODUCT

The identification plate contains the following data:

• serial number
• product name
• max. power (speed setting ‘high’)
• supply voltage and frequency

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 a 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

• Everyone working on or with the product must be familiar with the contents of this manual 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.
• Never change the order of the steps to perform.
• Always keep the manual with the product.

Intended use
The product has been designed exclusively for extracting 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 recognised 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.

PHV-I only; Germany-specific:
The TRGS 560 requirements on the recirculation of carcinogenic matter should be observed and adhered to when extracting welding fumes containing carcinogenic matter such as nickel and chrome.

WARNING

Fire hazard!
Never use the product for extracting inflammable, glowing or burning particles or solids or liquids. Never 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:

• MIG/MAG solid wire (GMAW)
• MIG/MAG flux cored wire (FCAW)
• Stick welding (MMA or SMAW)
• 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 that are released during the following (welding) processes:

• MIG/MAG welding robots with intensive use of TipDip or other anti-spatter products
• oxy-fuel or plasma cutting
• arc-air gouging
• (welding with) a release of a dense oil mist
• paint spraying
• extraction of hot gases (more than 40°C continuously)
• extraction of aggressive fumes (such as acids)
• grinding aluminum and magnesium
• thermal spraying (i.e. plasma etc.)
• extraction of cement, sawdust, wood dust, etc.
• sucking cigarettes, cigars, tissues, and other burning particles, objects, and acids
• any dangerous situations in which there is a risk of an explosion or fire

WARNING
Never reach into the intake or outlet of the fan.

Modifications
Modification of the product or any of its parts is not allowed.

TECHNICAL SPECIFICATIONS

General

Extraction volume (clean filter with 2,5 m hose and EN-20):

•       speed setting ‘low’

•       speed setting ‘high’

| ****

140 m3/h

230 m3/h

Filter surface main filter| 12 m2
Filter surface HEPA filter| 0,4 m2
Filter efficiency| 99,9% (incl. HEPA

filter H12)

PHV-I only:
The warning signal starts when the extraction capacity is less than 150 m3/h in the speed setting ‘high’.

Dimensions
See Fig 1 dimensions in mm.

Electric system
See the identification plate and the separate electrical diagram.

Power consumption:

• speed setting ‘low’: ±70%
• speed setting ‘high’: 100%

Ambient conditions

Sound pressure
The level of the A-weighed sound pressure is 70 dB(A) according to ISO 3746. Measurements were performed in the workshop with a PHV fitted with a welding torch.

GENERAL DESCRIPTION

The machine consists of the following main components (see Fig. 2):

• A. control panel
• B. fans
• C. mains cord
• D. air intake Ø 48 mm
• E. bottom
• F. pre-separator
• G. wheels
• H. integrated prefilter
• I. main filter Dura-H
• J. outlet cover
• K. HEPA filter
• L. top cover

General description

• The machine has been specially designed for extracting and/or filtering fumes and gases that are released during the most common light and medium welding processes.
• With its 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.

Operation
The machine works under the recirculation 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 prefilter 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 to the workshop via the outlet grid. With the optional hose connection HCH-45 the air can be discharged elsewhere, for example into the atmosphere.

The welding fumes can be extracted at the source in the following ways:

• A. by the supplied extraction hose Ø 45 mm connected to the welding torch 1;
• B. by the supplied extraction hose Ø 45 mm connected to the extraction nozzle 1.

INSTALLATION

Unpacking
Check that the machine is complete. The package should contain:

• portable welding fume extractor
• extraction hose 2,5 m/Ø 45 mm
• 4 carbon brushes
• user manual
• electrical diagram

Installation
The machine is ready for use.

CAUTION!

• Do not position the machine in places where it is exposed to vibrations or radiation from heat sources.
• Observe the ambient conditions as described.

Connection to the mains

CAUTION!
Make certain that the machine can be connected to the local mains. Specifications for supply voltage and frequency can be found on the identification plate.

USE

CAUTION!
Before use carefully read the safety regulations.

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.

Controls

PHV-I only:
A 2.5 m extraction hose is supplied standard with the product. Using this hose guarantees that the filter pollution indicator functions properly (w.r.t. the minimum extraction capacity) in ‘high’-mode. The extraction capacity will be reduced somewhat when using a longer hose; the warning signal will therefore be initiated earlier.

ATTENTION! (PHV-I only)
The extraction capacity will be less than 150 m3/h when a welding torch with integrated extraction is used. The filter pollution indicator will therefore be activated immediately.

ATTENTION! (PHV-I only)
The required underpressure 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. 3) contains the following controls:

• A. 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. Groove 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.

Use
PHV with welding torch + integrated extraction

Before use, carefully read the user manual of the welding torch.

• Connect the extraction hose Ø 45 mm at one side to the air intake of the machine and at the other side to the welding torch.
• Put the mass cable of the welding machine into the slit on top of the machine.
• 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.
• The machine continues to run for 15 seconds (in the ‘auto’ setting) after welding is completed.

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.

• Place the extraction nozzle at 2-4 cm from the source of pollution.
• Insert the mass cable of the welding machine into the slit on top of the extractor.
• 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.
• The machine continues to run for 15 seconds (in the ‘auto’ setting) after welding is completed.

When using the machine, regularly check that the extraction capacity is sufficient. When the extraction capacity decreases, the filters should be replaced. A decrease in extraction capacity may lead to a too high concentration of 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.

MAINTENANCE

The machine has been designed to function without problems for a long time with a minimum of maintenance. 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 per TRGS 560 (W2 and W3): Inspection and maintenance of the product shall be carried out in conformance with TRGS 560, chapter 5, paragraph 9.

• WARNING!
  Overdue maintenance may cause a fire.

• WARNING!

  • Always switch the machine OFF and remove the mains plug from the wall socket before carrying out the activities below.
  • First, read the maintenance regulations at the beginning of this manual.

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.

Clean the outside of the

machine with a non-aggressive detergent.

|  | X[1]|
Clean/empty the pre-separator.| X[1]|  |
---|---|---|---
Check the main filter for damage.| X[1]|  |
Check the seals of the main filter.|  |  | X
Clean the integrated aluminum prefilter at the bottom of the main filter and the separate aluminum prefilter using an industrial vacuum cleaner that meets dust class H according to EN 60335-2-69.| X[1]|  |
Check the mains cord for damages.| X[1]|  |

Replacing the filters
The main filter and the HEPA filter cannot be cleaned and therefore they have to be replaced periodically.

WARNING!
A saturated filter often contains dust and dirt particles. 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.
• 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. 4):

Replacement of the main filter
Use the plastic bag that contains the new main filter to exchange the filter for a new one. Draw the bag carefully over the old filter when removing the filter. After that close the bag with a tie wrap or similar. The pre-separator can also be emptied in the same bag.

• Loosen the side clips (A).
• Remove the top cover (B) from the machine.
• Carefully remove the main filter (C) from the bottom of the machine.
• Check the seals before placing a new filter. If the seals need to be replaced, contact your supplier.
• Place the new filter and mount the disassembled parts in reverse order. Check that the integrated aluminum prefilter is placed at the bottom.

Replacement of the HEPA filter
Use the plastic bag that contains the new HEPA filter to exchange the filter for a new one. Put the used HEPA filter carefully in the plastic bag and close it with a tie wrap or similar.

• Remove the outlet cover by loosening the two screws (D)
• Remove the HEPA filter (E).
• Place a new HEPA filter in the correct position (open side at the top); to facilitate this, apply some suds to the seals.
• 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.

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.

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 only be carried out by qualified personnel.

• Always replace all motor seals when replacing or carrying out maintenance on the motors.

Problem

| Possible cause|

Solution

---|---|---
The motor does not start.| No mains voltage.| Check the mains

voltage.

The supply cord is defective.| Repair or replace the supply cord.
Carbon brushes are worn.| Replace the carbon brushes.
Motor defective.| Replace both motors.
Extraction capacity is insufficient.| The main filter is polluted.| Replace both the main filter and the HEPA filter [1].
The extraction hose was damaged or leaked.| Replace the extraction hose [1].
Seals damaged or leaking.| Replace the seals.
The motor stops automatically.| Thermal protection is activated.| Check that the cooling slits underneath the top cover and/or the outlet are not obstructed.
---|---|---
Dust or smoke coming out of the outlet grid.| Filter torn or placed incorrectly.| Replace the filter or position it correctly [1].

If the supply cord is damaged, it must be replaced by the manufacturer its service agents, or a similarly qualified person to avoid hazards.

SPARE PARTS

For spare filters and parts available for the machine consult the exploded view (see Fig. 5). The machine is standard supplied with two sets of spare carbon brushes including seals.

• 0000102275 Pre-filter
• 0000102284 Tumbler switch 0-I (USA/Canada)
• 0328250010 Pressure switch (IFA)
• 0806010120 Handle black
• 9820034120 Carbon brushes (2 sets); 230V
• 9820034130 Carbon brushes (2 sets); 120V
• 9840251030 Motor 120V/60Hz, incl. seals
• 9840251040 Motor 230V/50-60Hz; incl. seals
• 9850040030 Wheel set (2 pieces, excl. wheel covers)
• 9850040040: Wheel covers yellow (2 pieces)
• 9850060140 HEPA filter H12
• 9850060230: Dura-H filter with integrated prefilter
• 9850070090 Activated carbon filter FAC-HV
• 9850070100 Top cover PHV; 230V/1ph/50Hz
• 9850070130 Draw latch (set of 2; to be ordered per 10 sets/2)
• 9850070150 Outlet cover
• 9850070200 Top cover PHV-I; 230V/1ph/50Hz
• 9850070700 Top cover PHV; 120V/1ph/60Hz
• 9850080140 Seals main filter (set)
• 9880030030 Control panel + PC board PHV; 120-230V/1ph/50Hz
• 9880030040 Control panel + PC board PHV; 120-230V/1ph/50Hz (IFA)
• 9880030050 Control panel + PC board PHV; 120V/1ph/60Hz (USA/Canada)

OPTIONS AND ACCESSORIES

The following options and accessories are available with the machine (see Fig. 6).

• 9850070080: FAC-HV – Activated carbon filter
• 7915303000: MBH – Wall bracket for stationary mounting
• 7900060050: HCH-45 – Hose connection outlet side for controlled discharge of filtered welding fume
• 7900060030: NKT – Nozzle kit with 2,5 m hose for standard welding gun; extraction above torch max. Ø 24,5 mm
• 7900060040: NKC – Nozzle kit with 2,5 m hose for standard welding gun; extraction around torch max. Ø 27,5 mm
• 7900060020: EN-20 – Funnel nozzle with magnetic foot and hose connection
• 7900060010: EN-40 – Slit extraction nozzle 40 cm with magnetic foot and hose connection
• 9880020100: H-2.5/45 – Extraction/exhaust hose, length 2,5 m, Ø 45 mm
• 9880020110: H-5.0/45 – Extraction/exhaust hose, length 5,0 m, Ø 45 mm
• 0809010040: CP-45 – Connection piece for two hoses Ø 45 mm

CE DECLARATION

CE declaration of conformity for machinery
We, Plymovent Manufacturing B.V., Wezelkoog 11, 1822 BL Alkmaar, the Netherlands, herewith declare, on our responsibility, that the product(s):

• PHV
• PHV-I

which this declaration refers to, are in accordance with the conditions of the following Directives:

• Machine Directive 2006/42 EC
• EMC 2004/108 EC
• LVD 2006/95 EC

Alkmaar, 30th November 2013

Ir. F. Coehoorn
Vice President Research & Development.

www.plymovent.com.

References

• Plymovent - Clean air at work

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