Esta DUSTOMAT 4 ECO+ User manual

THE WORLD OF EXTRACTION
TRANSLATION OF THE ORIGINAL OPERATION
MANUAL
DUSTOMAT 4 ECO+
Mobile deduster

Welcome to the wide world of extraction technology
With the purchase of an ESTA product you have chosen a
quality product which has been designed to the current state of
the art.
ESTA products provide clean air to the work place and
consequently guarantee better quality, longer machine running
times and above all, provide healthier working conditions.
We will be pleased to answer at any time your questions on any
aspect of extraction technology.
Your team from
ESTA Apparatebau GmbH & Co. KG
THE WORLD OF EXTRACTION

ESTA Apparatebau GmbH & Co. KG Imprint/copyright
09740-52-02-00_DUSTOMAT 4 eco+ 3 / 72
Imprint/copyright
© Copyright
This publication including all associated documents is protected by the laws
of copyright. Its use requires the prior written consent of ESTA Apparate-
bau GmbH & Co. KG, Senden. This applies in particular to all reproduction,
distribution, processing, translation, and microfilming; as well as storing and
processing in electronic systems, including databanks and on-line services.
Violations will incur damages.
The information in the document must be followed during operation in order
to avoid faults or damage. The operator must therefore make it available to
all relevant maintenance and operating staff. Subject to alteration.
Copyright notice per DIN ISO 16016
Transfer or reproduction of this document and use or communication of its
content are prohibited without explicit consent. Violations shall be liable for
damage compensation. All rights to patent, utility or design registration are
reserved.
The warranty can only be accepted if the following conditions are met:
=Professional transport
=Professional assembly, commissioning and operation using these oper-
ating instructions.
=Verifiable compliance with the prescribed maintenance intervals.
=Operation of the product with conveyed media having the specified
chemical and physical properties.
=Immediate reporting of damage to the manufacturer.
=Exclusive use of genuine replacement parts.
=Structural modifications to the original condition only to be carried out
with the agreement and written approval of the manufacturer.

Table of contents ESTA Apparatebau GmbH & Co. KG
4 09740-52-02-00_DUSTOMAT 4 eco+
Table of contents
1 General instructions..................................5
1.1 General notes prior to use ...........................5
1.2 Legal information .........................................5
1.3 Target group of the document .....................5
1.4 How to read this document.......................... 6
1.5 Form and significance of warning information
.....................................................................7
1.6 Explanation of symbols................................8
2 Product identification................................9
2.1 Symbols and labels used.............................9
2.2 Intended use................................................ 9
2.3 Improper use .............................................10
2.4 Foreseeable misuse ..................................10
2.5 Warranty terms ..........................................11
2.6 Important information on the product......... 11
3 Safety........................................................12
3.1 Hazard prevention .....................................12
3.2 Workstation ventilation ..............................15
3.3 Product safety............................................16
3.4 Qualified personnel....................................17
4 Structure and function ............................18
4.1 Illustration ..................................................18
4.2 Functional description................................19
4.3 Safety and monitoring devices ..................19
5 Transport and installation ......................20
5.1 Transport ...................................................20
5.2 Set-up ........................................................21
6 Commissioning........................................22
6.1 Ambient conditions for the product ............24
6.2 Pipeline connection ...................................25
6.3 Electrical connection..................................26
6.4 Pneumatic connection ...............................27
6.5 Preparing disposal unit ..............................27
6.6 Recording equipment ................................28
6.7 Operating and display elements ................29
6.8 Monitoring rotation direction ......................30
6.9 Activation operations for motors ................31
7 Operation..................................................32
7.1 Operating modes .......................................32
7.2 Operating the product................................ 33
7.3 Symbol description ....................................34
7.3.1 Potential-free contact (optional).................35
7.3.2 Timer function (optional)............................35
7.3.3 During operation ........................................36
7.3.4 Service menu.............................................37
7.4 Jet impulse cleaning ...................................39
7.4.1 Automatic cleaning......................................39
7.4.2 Manual cleaning..........................................40
7.4.3 Automatic post-cleaning..............................40
8 Servicing and maintenance .....................41
8.1 Operating and auxiliary materials ...............42
8.2 Maintenance table.......................................43
8.3 Visual inspection .........................................44
8.4 Functional check .........................................45
8.5 Check the filter elements ............................45
8.6 Emptying the compressed air tank..............46
8.7 Check safety valve......................................47
8.8 Checking the pipeline..................................47
8.9 Changing the filter cartridge........................48
8.10 Replacing filter mats ...................................50
8.11 Emptying the collection container ...............51
8.12 Clean the air guide plate .............................53
8.13 Cleaning the product...................................54
9 Faults and Rectification ...........................55
9.1 Product........................................................56
9.2 Fan and drive motor....................................57
9.3 Display error messages ..............................58
9.4 Display fault messages ...............................60
9.5 Messages....................................................61
9.6 Error codes .................................................62
10 Decommissioning .....................................63
11 Packing and storage.................................64
11.1 Packaging ...................................................64
11.2 Storage .......................................................65
11.3 Disposal ......................................................66
12 Technical data ...........................................67
12.1 Replacement parts list ................................68
13 EC/EU Declaration of Conformity............69

ESTA Apparatebau GmbH & Co. KG General instructions 1
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1 General instructions
1.1 General notes prior to use
Before using the product, it must be ensured that all persons about to use
the product or perform maintenance work on it,
=Have received all relevant information, instructions and training courses
for using the product and have understood them.
=Are able to perform or fulfil their tasks according to the law and the cur-
rent operating manual.
1.2 Legal information
To reduce potential risks posed by the product, the design and construction
of the product conform to the directives and standards listed in the EU/EC
declaration of conformity. Potential risks can only be minimised when the
user or its authorised representative adheres to the additional, relevant
standards for a product ready to install.
1.3 Target group of the document
This document is intended for
=Operators trained on the product who are familiar with the extraction
process.
=Trained assembly and maintenance personnel.
=Trained electrical specialists

1 General instructions ESTA Apparatebau GmbH & Co. KG
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1.4 How to read this document
This document is a component of the product it describes. Keep the instruc-
tions easily accessible at the place where the device is being used, so that
they can be seen by the staff at all times.
All persons must carefully read this document before any work on the
product takes place (commissioning, assembly, maintenance, etc.). Pre-
requisite for safe work and trouble-free handling is that all relevant informa-
tion, instructions and training for the use of the product and substances it is
used for have been obtained and understood. The tasks must be performed
or fulfilled according to the law and in accordance with this document.
Please follow the safety and warning instructions in the document and on
the product. All plant, operating, and work instructions of the owner-oper-
ator apply in addition to this document.
The document also contains graphical examples along with the descrip-
tions. For this reason, the equipment may differ somewhat from the de-
scriptions and representations.
Highlighting in the text
In order to simplify the legibility and overview, various paragraphs and in-
formation are highlighted by distinguishing elements.
The symbols have the following meaning:
=1st level list
–2nd level list
üHandling requirement
1. Handling step
ðIntermediate result
ðResult of the entire handling sequence
Information on the target group for whom the following instructions are in-
tended.

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1.5 Form and significance of warning information
DANGER
High risk
indicates an imminent hazard. If this is not averted, death or very serious
injury will result.
WARNING
Medium risk
indicates the possibility of an imminent hazard. If this is not averted, death
or very serious injury may result.
CAUTION
Low risk
indicates the possibility of an imminent hazard. If this is not averted, slight
or minimal injury may result.
NOTICE
Material damage
Foreseeable material damage for the product and environment with a fail-
ure to comply with the specified measures.
This warning is displayed when there is a thread of danger or damage. This
represents actions which can cause a risk of damage.
Warnings are indicated by a symbol or signal word. The warning includes
information on the type and source of the hazard, the consequences if it oc-
curs, and actions for averting it.

1 General instructions ESTA Apparatebau GmbH & Co. KG
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1.6 Explanation of symbols
Warning notices General warning signs Electric voltage
Hearing damage Toxic dusts
Danger of crushing
Hand injuries
Falling/tipping hazard
Suspended load Automatic start-up
Prohibition symbols General prohibition Read the manual
Wear ear defenders Wear safety goggles
Wear safety footwear Wear a hard hat
Wear gloves Use breathing equip-
ment
Wear protective cloth-
ing
Enable before mainten-
ance or repair work
Further information Reference to target
group

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2 Product identification
2.1 Symbols and labels used
The ESTA service label indicates when and by whom the last service was
carried out by the ESTA maintenance service. It also lists when the next
service by the ESTA maintenance service is scheduled.
Product name plate (sample name plate)
1 Switch the product off.
2 Wait 5 minutes.
3 Pull out the collection drawer or open the product.
Do not take in glowing dust or other sources of ignition. Do not use in con-
junction with spark-generating machinery.
2.2 Intended use
The product was designed for use at the following workplaces:
=Individual work station
=Group work station
=A central extraction system on dust-generating machinery
=A central extraction system on chip-generating machinery
Coordinate any deviating applications with the manufacturer to ensure that
the functioning of the product is not compromised.
The product has been manufactured based on state-of-the-art technology
and according to recognised safety regulations and must be used appropri-
ately and as follows:
=For commercial use, such as in industrial enterprises and workshops.
=For the extraction of dry dust
=For the extraction of free-flowing dust
=For the extraction of non-explosive dust

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2.3 Improper use
The product may only be used within the scope of the technical data spe-
cified by ESTA. Uses that exceed the specifications in “Intended Use” are
deemed to be inappropriate. The manufacturer is in this case not liable for
resulting damage.
Examples of inappropriate use are:
=Using or storing the product outdoors
=Use in dust or gas EXPLOSION areas
=Extraction of highly flammable or glowing particles
=Extraction of process air outside the specified temperature range, see
Ambient conditions for the product [}24]
=Extraction of liquids
=Extraction of corrosive gases
=Extraction of moist or fluid substances
=Extraction of oily parts
=Installation in paint shops
=Installation in food operations
2.4 Foreseeable misuse
The use of the product in an unintended way, but which can arise from eas-
ily foreseeable human behaviour.
This includes for example:
=Installing outdoors
=Installation or operation in explosive dust and gas environments
=Unauthorised modifications to the product
=Intake of glowing embers such as, e.g., cigarettes
=Start-up of the product despite defects detected on the product or at-
tached parts (e.g., pipeline)
=Intake of items not suitable for suction (e.g., mobile phone, tool, glove,
screws, etc.)
=Closing of intake opening

ESTA Apparatebau GmbH & Co. KG Product identification 2
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2.5 Warranty terms
ESTA accepts no liability for direct damage and consequential damage to
products or for personal injuries when the product is not used for its inten-
ded purpose. The operating company must prove that the fault was not
caused by inappropriate installation, assembly, maintenance or use of the
product.
For your own safety, use only genuine replacement parts and accessories.
ESTA accepts no liability for any resulting damage if other products are
used.
2.6 Important information on the product
Responsibility must be clearly stipulated for the following tasks:
=Transport
=Assembly
=Commissioning
=Operation
=Maintenance and repair
=Cleaning
=Decommissioning
=Disposal

3 Safety ESTA Apparatebau GmbH & Co. KG
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3 Safety
3.1 Hazard prevention
DANGER
Electric shock from high voltage
Severe injury including death possible
4Any work on the electrical grid and on live components may only be per-
formed by an electrician.
4Follow the safety rules for working with electrical products.
4Shut down the product or any live components before working on them
and secure them against reactivation (e.g. padlock).
4Establish electrical connections of the components according to the
manufacturer's specifications.
4Protect the power supply cables against damage and dimension them
according to the power uptake of the drive motor.
4Perform the electrical installation and connection of the drive motor ac-
cording to the regionally applicable regulations (e.g. VDE), the legal
standards of the country and the rules of the regional power company.
4Regularly check the power cable for damage and wear.
4If damage is found to the product or power cable, it must not be put into
operation and the product must be secured against being switched on
again. (Padlock on main switch)
4Have any damaged cable replaced by specialised staff.
4Do not clean electrical components with a water jet.
4Check existing protective devices and adjust them to the working pro-
cess of the product.
DANGER
Danger of fire due to sparks and glowing particles
Severe injury including death possible
4Keep combustible, flammable materials away from the work area.
4Never run away if clothing catches fire. Extinguish flames by rolling on
the ground or by smothering them with blankets.
4If there is a fire, alert the fire department immediately, and contain the
fire by appropriate means.
4Keep a suitable extinguishing agent (not included in scope of delivery)
near the product before start-up and during operation.

ESTA Apparatebau GmbH & Co. KG Safety 3
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DANGER
Risk of falling and tripping
Danger to life from falling objects or loads
4Do not stand under suspended loads.
4Secure the assembly area and mark it out (e.g., with barrier tape).
4Always lift the product vertically during loading and assembly work.
4Only transport the product with suitable, approved means of lifting and
transport.
4Keep a sufficient distance from the product while it is being installed.
Distance at least 1.5 times the height of the product.
4Wear personal protective equipment.
4Seal the intake port with a sealing plug so it is dust-tight during transport-
ation.
DANGER
Risk of fire due to deposits
Deposits from dust trails and particles can cause a fire on the baffle/air
baffle
4Remove adhesions and deposits from the baffle/air baffle and the in-
spection cover regularly.
4Prevent spark ingress into the baffle/air baffle.
WARNING
Danger of crushing due to loose or open covers
Injuries to the limbs
4Keep covers tightly closed during operation.
4Ensure that inspection doors are firmly closed.
4Check regularly that fastening screws and component connections are
secure.
4Only start up the product after the assembly is complete and correct.

3 Safety ESTA Apparatebau GmbH & Co. KG
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CAUTION
Toxic dusts
Short-term impairment of the respiratory organs during inhalation
4Maintenance, cleaning, repair, and emptying work may only be com-
pleted by expert personnel.
4Wear personal protective equipment.
4Seal the intake port with a sealing plug so it is dust-tight during transport-
ation.
4Only operate the product with the filter elements installed.
4Regularly check the filter elements for clogging.
4Ensure that the collection container is attached to the discharge opening.
4Ensure that inspection doors are firmly closed.
4During operation, do not change the product’s location.
4Always complete all maintenance and upkeep work in a well-ventilated
room.
4Do not blow out or beat out the filter elements when they are disas-
sembled.
4Dispose of used filter elements in air-tight-sealed disposal bags in ac-
cordance with regional regulations.
CAUTION
Dust deposits in the pipe system
Short-term impairment of the respiratory organs during inhalation
4Check the connected piping system regularly for dust deposits.
4Observe the minimum air speed required for use and the resulting min-
imum airflow volume.
CAUTION
Release of compressed air pulses when filter elements are be-
ing cleaned
Risk of hearing damage
4Wear personal protective equipment.
4Do not open the product during cleaning.
4Ensure that inspection doors are firmly closed.
4Only open the inspection doors when the compressed air tank is pres-
sure-free.
4Wait for the automatic post-cleaning to end.
4Disconnect the compressed-air supply from the product.
4Empty the compressed air tank.

ESTA Apparatebau GmbH & Co. KG Safety 3
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CAUTION
Self-acting movement
Minor injuries to body or limbs
4Always make sure that the castor’s lock is activated during placement.
4Make sure that the surface can be driven on, is level and sufficiently load
bearing.
4Wear personal protective equipment.
NOTICE
Damage to the casters
4Observe the maximum permissible load capacity of the casters.
4Maintain the casters regularly.
4Lubricate the casters regularly with oil or grease in accordance with the
general rolling bearing regulations depending on the temperature or the
risk of dirt.
3.2 Workstation ventilation
The provisions of DGUV rule 109-002 must be complied with.
During extraction, the volume flow returned from the product into the room
should be no more than 50% of the supply air. With open room ventilation,
supply air flow should be assumed as equal to 1x the room volume every
hour. This means that the rate of air replacement must be 1/h.
Calculation Supply air flow [m³/h] = room volume [m³] x air replacement rate [1/h]
Example:
When the product 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 ventil-
ation if the volume of the work room is 1,060 m³ (e.g., 353 m² surface x 3 m
ceiling height).

3 Safety ESTA Apparatebau GmbH & Co. KG
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3.3 Product safety
The following points must be considered to avoid injuries and other risks
due to inappropriate use and operation of the product:
=Assembly, electrical connection, maintenance, initial operation, clean-
ing, repair and other work in connection with the product may only be
performed by trained specialists.
=The product must be checked for faulty or damaged supply lines
(cables, pipe systems, etc.), connections and open system parts (in-
spection door, discharge opening) every time before starting up. Do not
use the product in such cases and immediately notify the maintenance
personnel responsible.
=The product may only be operated when it is ready for operation, when
the inspection doors are shut and when the toggle-type fasteners of the
collection container are firmly closed.
=Ensure before any work is performed on the product or before inspec-
tion doors are opened that the product is disconnected from the power
supply and secured against unauthorised reactivation.
=Disconnect the compressed air supply and empty the compressed air
tank before carrying out any work.
=Connect the product to the electrical power supply properly and in pre-
cise compliance with the safety instructions and use it exclusively in ac-
cordance with the specifications.
=In all emergencies, disconnect the product from the power supply imme-
diately.
–Switch off the product at the main switch and secure it against re-
operation.

ESTA Apparatebau GmbH & Co. KG Safety 3
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3.4 Qualified personnel
Trained personnel Trained personnel are those who have been instructed in the correct hand-
ling of the product and who are aware of the risks presented by improper
use. Personnel must receive instruction on safety equipment. Knowledge of
this manual is mandatory.
Qualified semi-skilled
technicians
An employee with appropriate technical training, knowledge and experience
who is able to identify and avoid hazards. Knowledge of this manual is
mandatory.
Trained skilled worker Qualified technician in a qualified profession. Knowledge of this manual is
mandatory.
Target group Task Qualification Protective
equipment
Transport
personnel
Transport
Set-up
Qualified semi-
skilled technicians
Installation
personnel
Installation Trained skilled
worker
Commissioning
personnel
Commissioning Trained skilled
worker
Operating
personnel
Operation Qualified semi-
skilled technicians
Maintenance per-
sonnel
Inspection
Maintenance
Repair work
Trained skilled
worker
Maintenance,
cleaning
personnel
Maintenance
Clean
Trained personnel

4 Structure and function ESTA Apparatebau GmbH & Co. KG
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4 Structure and function
4.1 Illustration
1
2
9
4
3
2
5
6
7
8
1 Outlet opening clean air 4 Air guide plate inspection opening
2 Lifting device 5 Control panel
3 Compressed air tank cleaning 6 Filter unit
7 Raw gas intake opening 8 Disposal unit
9 Fan unit

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4.2 Functional description
Procedure principle Room air is extracted using a vacuum in a collection system (e.g. extraction
arm, extraction hood) and then dust/smoke is removed in a filter unit. The
suction unit attached to the product generates an air current and returns the
cleaned air to the atmosphere via the outlet opening.
Filter unit Due to the negative pressure produced by the fan, air is sucked in through
the corresponding filter unit. The permanent filter in the filter unit separates
the dust from the extracted air.
The purified air is fed back into the room through the outlets on the top of
the fan unit.
Fan The product is equipped with a three-phase motor which drives a radial fan.
The fan is turned on and off at the control panel.
Air guide plate The air guide plate acts as a filter pre-separator and is installed in the in-
take duct. The air sucked in is guided in a targeted manner and coarse
particles are separated through the plate, which prevents the filter elements
from being damaged. The air guide plate improves the service life of the fil-
ter cartridges.
Disposal unit Dust that is generated during the cleaning process is collected in the dis-
posal unit below the filter unit. The collection drawer is lowered and pulled
out for easier disposal of the collected material. Depending on the type of
material collected, a collecting container can also be used, which is sealed
tight together with the collected material for low-dust disposal in accord-
ance with the local regulations.
4.3 Safety and monitoring devices
Main switch Main switch for turning the product on and off. EMERGENCY-OFF switch,
which can be secured with a lock against unintentional activation.
Differential pressure
measurement
The minimum volume flow is monitored via the differential pressure of the
control system.
Motor protection switch If the motor protection switch has tripped, the extraction operation stops
and reactivation of the extraction is not possible.
Safety valve The safety valve monitors the pre-set activation pressure. As soon as the
air reaches or exceeds the set pressure, the valve opens and allows the
compressed air to escape. Once the pressure has regulated to normal, the
valve closes again.

5 Transport and installation ESTA Apparatebau GmbH & Co. KG
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5 Transport and installation
TARGET GROUP: Transport personnel
5.1 Transport
DANGER
Risk of falling and tripping
Danger to life from falling objects or loads
4Do not stand under suspended loads.
4Secure the assembly area and mark it out (e.g., with barrier tape).
4Always lift the product vertically during loading and assembly work.
4Only transport the product with suitable, approved means of lifting and
transport.
4Keep a sufficient distance from the product while it is being installed.
Distance at least 1.5 times the height of the product.
4Wear personal protective equipment.
4Seal the intake port with a sealing plug so it is dust-tight during transport-
ation.
WARNING
Crushing hazard when setting the product down
Injuries to the hands and feet
4Secure the product against tipping and falling during transport.
4Set the product down carefully and cautiously during set-up.
4Wear work gloves and safety shoes.
NOTICE
Material damage due to improper transport
Damage to the housing, lines and product components
4Do not push or pull the product across the floor if it does not have any
rollers.
4Seal the intake port with a sealing plug so it is dust-tight during transport-
ation.
4Pay attention to any protruding components when setting down the
product.
4Note the centre of gravity (which is not in the centre) when setting down
the product.
4Make sure that the surface can be driven on, is level and sufficiently load
bearing.