Esta FILTOWER F-100 User manual

The World of Extraction
OPERATING INSTRUCTIONS
FILTOWER F
Hall Ventilation System

Your purchase of an ESTA machine has
been a good decision. The design of
our quality products complies with the
latest state of the art. ESTA products
have been devised to provide for clean
air at the workplaces at which they are
applied. This results in an even more
enhanced level of quality and longer
machine times and, particularly, healthier
working conditions. Should you have
any questions pertaining to suction tech-
nology issues, please feel free to contact
us at any time. Our experts will be gladly
at your disposal.
Your ESTA Absaugtechnik Team
The World of Extraction
www.esta.com
Welcome to the sphere of suction
technology

Operating Instructions
FILTOWER F
Fan unit
FILTOWER F-100 (Order no.: 667,100)
FILTOWER F-160 (Order no.: 667,160)
FILTOWER F-200 (Order no.: 667,200)
and variations
Do not use this device unless you have
read the operating instructions and understood them.
Original operating instructions
667100A-08-02

Contents
2
FILTOWER F
667100A-52-02
Edition notice
Original operating instructions
Document no.: 667100A-08-02
Publishing date: 15.11.2016
Type of device: FILTOWER F fan unit
Article no.: 667.100 // 667.160 // 667.200 and variants
Publisher
ESTA Apparatebau GmbH & Co. KG Tel.: [phone]
Gotenstr. 2-6 Fax: [phone]
89250 Senden Email: [email protected]
Germany www.esta.com
Copyright notice (per DIN ISO 16016:2007-12)
Transfer or reproduction of this document, or the use or communication of its content, is forbidden
without explicit consent. Violators will be liable for damages. All rights to patent, utility or design
registration are reserved.

Contents
667100A-52-02
FILTOWER F fan unit
3
Contents
Contents.................................................................................................................................3
1General instructions........................................................................................................5
1.1 Target group.............................................................................................................5
1.2 Tips ..........................................................................................................................6
2Product identification......................................................................................................7
2.1 Technical Data .........................................................................................................7
2.2 Intended application.................................................................................................8
3Product description.......................................................................................................10
3.1 Device image FILTOWER F...................................................................................10
3.2 Functional description ............................................................................................11
4Safety..............................................................................................................................12
4.1 Hazard categories..................................................................................................12
4.2 Symbol explanation................................................................................................12
4.3 General safety instructions.....................................................................................14
4.4 Preventing mechanical hazards .............................................................................14
4.5 Preventing electrical hazards .................................................................................15
4.6 Preventing dust hazards.........................................................................................16
4.7 Fire prevention .......................................................................................................16
4.8 Preventing noise hazards.......................................................................................17
5Delivery and commissioning........................................................................................17
5.1 Delivery and transport............................................................................................17
5.2 Connection.............................................................................................................18
5.3 Function check.......................................................................................................23
5.4 Commissioning.......................................................................................................24
5.5 Troubleshooting during commissioning..................................................................26
6Operating instructions..................................................................................................27
6.1 Operating the device ..............................................................................................27
6.2 Jet pulse cleaning...................................................................................................28
7Maintenance & troubleshooting...................................................................................30
7.1 Maintenance instructions........................................................................................30
7.2 Inspection and maintenance intervals ....................................................................32
7.3 Filter mat, outlet element........................................................................................34
7.4 Clean the air guide plate ........................................................................................36
7.5 Replacing filter cartridges.......................................................................................36
7.6 Clean the device.....................................................................................................36
7.7 Store the device .....................................................................................................37
7.8 Eliminating faults....................................................................................................37
8Disposal .........................................................................................................................39
8.1 Disposal of collected material.................................................................................39
8.2 Dispose of the device.............................................................................................39
9Optional equipment.......................................................................................................40
9.1 Potential-free contact .............................................................................................40
9.2 Operation with a frequency converter.....................................................................40
9.3 Activated carbon inserts in outlet............................................................................40
9.4 W3-Box for minimum volume flow check................................................................40
10 EC/EU Declaration of Conformity.................................................................................41
Notes.....................................................................................................................................42
Notes.....................................................................................................................................43

Contents
4
FILTOWER F
667100A-52-02
Notes.....................................................................................................................................44

General instructions
667100A-52-02
FILTOWER F fan unit
5
1 General instructions
1.1 Target group
This guide is aimed at the following target groups:
Task
Target group
Qualification
Protective equip-
ment
Transportation
Warehouse and
logistics staff
Essential knowledge
of the warehouse
and transport indus-
try
- Safety shoes
- Safety helmet
- Work gloves
Installation
Commissioning
Operation
Trained operating
personnel
Basic knowledge of
the extraction pro-
cess and the ex-
tracted material
- Hearing protection
- Safety shoes
- Safety helmet
- Work gloves
Troubleshoot-
ing
Electrical special-
ist
Technical training
with knowledge and
experience for identi-
fying and preventing
hazards posed by
electricity
- Hearing protection
- Safety shoes
- Work gloves
Servicing /
Cleaning
Trained cleaning
personnel
Essential knowledge
of the extracted ma-
terials and how these
should be handled in
accordance with lo-
cal regulations
- Hearing protection
- Safety shoes
- Work gloves
-Particle filter masks
Maintenance
Trained mainte-
nance personnel
Essential knowledge
of the extracted ma-
terials and how these
should be handled in
accordance with lo-
cal regulations
- Hearing protection
- Safety shoes
- Work gloves
-Particle filter masks
Electrical special-
ist
Technical training
with knowledge and
experience for identi-
fying and preventing
hazards posed by
electricity
- Safety shoes
- Hearing protection
- Work gloves

General instructions
6
FILTOWER F
667100A-52-02
1.2 Tips
Before operation, all persons who are to use the device or perform maintenance
on it must be provided with information, instructions and training in using the device
and on the substances for which it is to be used, including the procedure for safe
disposal of the collected material. Responsibilities must be clearly established for
the following
Installation
Commissioning
Operation
Maintenance and repairs
Read the instructions carefully before working with the device.
The device must be used only by persons who have been instructed in its handling
and are explicitly authorised to use it.
Always keep the instructions at the place where the device is being used, so that
they can be seen by personnel at all times.
These instructions describe the device at the time of first delivery following manu-
facture.
Keep the documents throughout the device's service life.
Pass these and other supplementary documents on to any subsequent
owners or users.
Add all changes to the documents that they obtain.
Check the completeness of the documents and pay attention to their content.
Further documents are available on top of these instructions. You can request any
documents required from ESTA.
Fan unit control manual
additional maintenance instructions for the filter unit filter
Additional maintenance instructions for the filter unit: disposal
Where applicable, instructions on optional equipment

Product identification
667100A-52-02
FILTOWER F fan unit
7
2 Product identification
2.1 Technical Data
We reserve the right to make technical changes // Observe the specifications on the rating plate
Item no.
667100
667160
667200
Model FILTOWER
F-100
F-160
F-200
Drive power
[kW]
2 x 3.0
2 x 4.0
2 x 7.5
Connection voltage
[V]
400
Nominal frequency
[Hz]
50
60
50
60
50
60
Nominal current
[A]
8.5
___**
12
20.2
___**
Circuit breaker
[A]
C16A
C32A
Protection class
IP 54
Max. vacuum
[Pa]
2,800
___**
2,800
___**
2,800
___**
Max. volume flow
[m³/h]
10,000
___**
15,000
___**
20,000
___**
Average sound pressure level LpA*
[dBA]
68
75
78 / 63*
Dimensions L x W x H
[mm]
2,060 x 1,515
x 3,000
2,060 x 1,515
x 3,310
2,060 x 1,515
x 3,810
Total weight
[kg]
approx. 900
approx. 1,100
approx. 1,400
Production year
See model plate
* using the enveloping surface method DIN EN ISO 3744, measured at minimum volume flow; noise measurement margin
of error approx. 4 dBA
** Custom voltage on request

Product identification
8
FILTOWER F
667100A-52-02
2.2 Intended application
2.2.1 Ambient conditions
Ambient temperature
[°C]
540
Rel. humidity
[%]
30 - 70
Min. spatial requirement around the
device
Operator's side (front)
Right
Left
Rear
Top
[mm]
1,500
1,000
1,000
1,500
1,000
2.2.2 Intended use
The device has been manufactured based on state-of-the-art technology and ac-
cording to recognized safety regulations and must be used as intended:
For commercial use, such as in industrial enterprises and workshops.
For the separation of dry, non-flammable welding fumes.
For the separation of smoke from unalloyed and low-alloy steels; e.g. with
low nickel and chrome content.
As a central extraction system for multiple welding workstations.
Only for dry cleaning.
Other applications are considered unintended use. ESTA is not liable for damages
due to unintended use!

Product identification
667100A-52-02
FILTOWER F fan unit
9
2.2.3 Improper use
The device has been manufactured accordingto the state of the art and recognized
safety regulations. Unintended use may cause hazards.
Therefore:
Not for the extraction of flammable welding fumes.
Do not use or store outdoors or in wet conditions.
Do not change the location of the device during suction operation.
Do not set up or operate in dust/gas-explosive areas.
Do not use in painting operations.
Do not connect to processing machines that may produce active ignition
sparks or hot embers.
Do not suck up liquids.
Do not suck up aggressive gases.
2.2.4 Reasonably foreseeable misuse
Do not suck up hot embers, such as cigarette butts.
Do not cause complete closure of the suction openings.

Product description
10
FILTOWER F
667100A-52-02
3 Product description
3.1 Device image FILTOWER F
Filter unit
Fan unit
Disposal unit
Control unit

Product description
667100A-52-02
FILTOWER F fan unit
11
3.2 Functional description
3.2.1 FILTOWER F-100 & F-160
The device is equipped with two three-phase motors which each drive a radial fan.
The device is supplied with or disconnected from the requisite power via the de-
vice's main switch. After activation with the device's main switch and switching on
at the two motor circuit breakers, the device starts up immediately.
The vacuum created by the fans draws in air through the inlet opening of the de-
vice. Permanent filters located in thefilter unit separate the dust and welding fumes
contained in the air which is sucked in. The purified air is guided back into the room
through the outlets.
The device is fitted with a pre-separator / air guide plate. This pre-separator/air
guide plate is installed in the intake port, which pre-separates coarse particles and
thus prevents these coarse particles being sucked against the filter.
A control unit is integrated into the device. The control unit monitors the volume
flow and controls the cleaning of the filter. If the value set in the control system for
the minimum volume flow is reached during operation, this is visually displayed on
the control panel. At the same time, the filter cartridges are cleaned automatically
with compressed air. A pneumatic jet pulse cleaning device is integrated within the
device's filter unit for this very purpose. The filters are freed from dust and regen-
erated through this cleaning.
The disposal unit attached below the filter collects the dust that has been cleaned
off. The collection drawer is lowered and pulled out for easier disposal of the col-
lected material. Depending on the material collected, disposal cartons can be in-
serted into the collection drawer, which are disposed of together with the collected
material.
3.2.2 FILTOWER F-200
The device is equipped with two three-phase motors which each drive a radial fan.
The device is supplied with or disconnected from the requisite power via the de-
vice's main switch. After activation with the device's main switch and switching on
at the On/Off switch, the device starts up immediately.
Its other functions are the same as the FILTOWER F-100 and F-160.

Safety
12
FILTOWER F
667100A-52-02
4 Safety
4.1 Hazard categories
Safety instructions and cross-topic information are indicated in this manual by sym-
bols.
Based on the severity of the hazard, the hazard warnings are categorized as fol-
lows:
DANGER
Hazard warning about an immediate danger to people.
Failure to comply can lead to severe injury or death.
WARNING
Warning about a recognisable hazard.
Failure to comply can lead to severe injury or death, and can destroy the device
or parts thereof.
CAUTION
Instruction about a hazard.
Failure to comply can lead to mild injury and to damage to the device.
NOTE
Instruction about a hazard.
Failure to comply can lead to damage to the device.
4.2 Symbol explanation
Further information
Reference to ESTA customer service
Reference to legal regulations

Safety
667100A-52-02
FILTOWER F fan unit
13
4.2.1 Symbols on the device
Before commissioning, read and observe the operating instructions and safety
instructions (as per ISO 11684).
1. Switch off the device.
2. Wait 5 minutes.
3. Then pull out the collection drawer or open the device.
ESTA service label. Show when and by whom the last maintenance was carried
out by the ESTA maintenance service and when maintenance is next planned
by the ESTA maintenance service.

Safety
14
FILTOWER F
667100A-52-02
4.3 General safety instructions
During extraction, the volume flow returned from the device into the room should
be no more than 50% of the air supplied. With open room ventilation, supply air
flow should be assumed as equal to the room volume every hour. This means that
the rate of air replacement must be once per hour.
Supply air flow [m³/h] = room volume [m³] air replacement rate [1/h]
Example:
When the device is operating at the nominal airflow volume of 1,060 m³/h, the
same volume of fresh air must be fed in. This occurs with natural ventilation if the
volume of the work room is 1,060 m³ (e.g., 353 m² surface with a 3 m ceiling
height).
According to work equipment user directives 2009/104/EG and TRGS 560, safety
devices for prevention or removal of hazards must be regularly maintained and
regularly inspected by an expert for safe, flawless operation.
In all emergencies, the device must be disconnected from the power supply imme-
diately, turned off at the main switch and the plug pulled immediately.
If there is a fire, alert the fire department immediately, and contain the fire by ap-
propriate means. Therefore keep a suitable extinguishing agent near the device
before start-up and during operation.
4.4 Preventing mechanical hazards
WARNING
Crushing hazard due to loose or open covers during operation
Keep covers tightly closed during operation!
WARNING
Tripping hazard when collection drawer is pulled out.
Always pay attention to the local accident prevention regulations.
Keep a distance from the device when you are not working with it.
All movable machine parts driven by electric motors must be covered by fixed,
securely fastened protective covers that can be removed only with tools.

Safety
667100A-52-02
FILTOWER F fan unit
15
4.5 Preventing electrical hazards
DANGER
Electric shock from high voltages
Follow the safety rules for working with electrical devices!
Secure the device against reactivation with a padlock!
Isolate device!
Any work on the electrical grid and on voltage-conducting parts may only
be performed by an electrical specialist.
DANGER
Electric shock from high voltages if customer's power cable is damaged
Do not damage by running over, crushing, straining, etc.
Regularly check the local power cable for damage and ageing.
Do not use if damage has been found on the power cable!
Any work on the electrical grid and on voltage-conducting parts may only
be performed by an electrical specialist.
Use only original ESTA replacement parts.
DANGER
High-voltage electric shock when working on the open switch box
Turn off at the device's main switch and secure with a padlock against re-
activation!
Isolate device!
Any work on the electrical grid and on voltage-conducting parts may only
be performed by an electrical specialist.
DANGER
Residual hazard from loose or open covers
Keep covers closed during operation!
Any work on the electrical grid and on voltage-conducting parts may only
be performed by an electrical specialist.
All electrical parts must be covered by fixed, securely fastened protective covers
that can be removed only with tools. The device complies with Protection Class I
according to EN 60335.
After use, before moving the device to another site and before cleaning, mainte-
nance, or replacement or removal of movable parts, switch off the device at the
device's main switch and cut it off from the mains.

Safety
16
FILTOWER F
667100A-52-02
4.6 Preventing dust hazards
CAUTION
Damage due to dust release
Maintenance, cleaning, repair and emptying work must be done only by
expert personnel.
Wear personal protective gear.
- Respirator mask (particle filter class P3)
- Protective clothing
- Protective gloves
Set up locally filtered forced-air ventilation where the device is being main-
tained, inspected or cleaned.
Operate the device only with the complete filtration system.
CAUTION
Damage from dust build-up in the device.
Observe the minimum air speed required for your application and the re-
sulting minimum airflow volume.
When removing the dust collection cartons and the collection
drawer, dust inhalation cannot be ruled out. That is why all ser-
vicing, cleaning and maintenance procedures, including the re-
moval and emptying of the collection drawer, are only to be per-
formed by specialist personal with personal protective equip-
ment.
The people assigned to cleaning work must be instructed on the
aspirated toxic materials. Harm to bystanders and the environ-
ment must be prevented by all means. Clean the maintenance
area thoroughly once maintenance is complete.
4.7 Fire prevention
WARNING
Fire hazard due to welding of oil-covered parts.
Carry out internal measures (checks, cleaning) to prevent oily, flammable
deposits from forming on the inside.

Delivery and
commissioning
667100A-52-02
FILTOWER F fan unit
17
4.8 Preventing noise hazards
CAUTION
Danger of hearing damage from release of compressed air impulses when filter
elements are being cleaned
Keep device covers closed.
Wear hearing protection.
Only open the device with the compressed air tank depressurised.
To do this:
- Switch off suction on the control unit.
- Wait for the automatic post-cleaning to end
- Disconnect the compressed air supply from the device.
- Empty the compressed air tank –through the control system if nec-
essary.
Only open the device when stopped.
To do this:
- Turn the device off at the main switch.
- Cut off the power supply.
The manometer attached to the compressed air tank is used for monitoring the
pressure in the tank.
After use, before moving the device to another site and before cleaning, mainte-
nance, or replacement or removal of movable parts, disconnect the compressed
air.
5 Delivery and commissioning
5.1 Delivery and transport
DANGER
Danger from falling device
Do not walk under heavy loads.
The lifting and transporting equipment must be designed for the weight of
the device.
WARNING
Crushing hazard if the device settles during transport
Secure the device during transport.
Wear safety shoes.

Delivery and
commissioning
18
FILTOWER F
667100A-52-02
CAUTION
Risk of damaging the device due to improper transport.
Do not push the device over the floor if it does not have any rollers.
Use only suitable lifting and transport equipment (such as a forklift or lift
truck) when transporting the device to its set-up location.
Watch out for the centre of gravity –which is not in the centre –when po-
sitioning.
Make sure the floor has adequate weight capacity and can be properly driven on
when transporting the device.
Permitted sling gear:
Lifting belt
Round sling
Permitted lifting gear:
Forklift trucks
Crane
Pallet truck
Upon delivery inspect the device for transportation damage. Damage determined
must be reported and documented immediately.
At delivery, the device is fastened to a pallet.
Remove the protective cover and floor securing devices.
Check the delivery is complete.
Attach the device to a permitted sling gear (e.g. lifting belt, round sling) at
the positions provided by the eye bolts on the roof.
Lift the device from the pallet using a crane, and place it upright on the
immediately adjacent floor.
Pay attention to the weight of the device and its centre of gravity during all
transport work.
ESTA customer service: [phone] - 0
5.2 Connection
Before establishing cable connections between the device and the mains, check
whether the operating voltage specified on the rating plate matches that of the
mains.
Place the device on an even surface as close as possible to the dust source. En-
sure the device is aligned horizontally when setting it up.