Esta DUSTOMAT-10 User manual

The World of Extraction
OPERATING INSTRUCTIONS
DUSTOMAT-10
Mobile Dust Extractors
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QUALITY

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 manual
DUSTOMAT-10
Item No. 09.201 (DUSTOMAT-10 (230V))
Item No. 09.215 (DUSTOMAT-10 (400V))
Do not use this device unless you have
read the user manual and understand it.
Translation of the original instructions
09201-08-01

09201-52-01 DUSTOMAT-10 2
Edition notice
Original operating manual
Document No.: 09201-08-01
Publishing date: 23.02.2012
Type of device: DUSTOMAT 10
Item No.: 09.201 // 09.215 and variants
Publisher
ESTA Apparatebau GmbH & Co. KG Tel.: [phone]
Gotenstraße 2-6 Fax: [phone]
89250 Senden E-mail: [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.
Warnings and safety instructions
Electrical current hazard
Note
Reference to ESTA customer service
Reference to legal regulations

09201-52-01 DUSTOMAT-10 3
Contents
Contents .....................................................................................................................................3
1.General safety notes ...........................................................................................................4
2.Preventing mechanical hazards.........................................................................................6
3.Preventing electrical hazards.............................................................................................6
4.Preventing dust hazards.....................................................................................................6
5.Intended use ........................................................................................................................7
6.Technical data and description..........................................................................................8
6.1 DUSTOMAT-10 ..................................................................................................................8
6.2 Functional description.........................................................................................................9
7.Delivery and commissioning ............................................................................................ 10
7.1 Delivery and transport ......................................................................................................10
7.2 Commissioning................................................................................................................. 10
8.Maintenance and troubleshooting ................................................................................... 12
8.1 Maintenance instructions..................................................................................................1 2 
8.2 Inspection and maintenance intervals ..............................................................................13
8.3 Troubleshooting................................................................................................................ 15
9.Monitoring the minimum volume flow .............................................................................16
9.1 Dust extractor - operation .................................................................................................16
9.2 Industrial dust extractor - operation ..................................................................................17
10.Cleaning .............................................................................................................................17
10.1 Cleaning the filter............................................................................................................ 17
10.2 Filter replacement...........................................................................................................18
11.Disposal ............................................................................................................................. 19
11.1 Disposing of collected dust materials .............................................................................19
11.2 Disposing of the dust extractor .......................................................................................20
12.Optional equipment...........................................................................................................21
12.1 Pre-separator ................................................................................................................. 21
13.Device diagram..................................................................................................................22
14.Declaration of conformity .................................................................................................23
Notes.........................................................................................................................................24

09201-52-01 DUSTOMAT-10 4
1. General safety notes
Before operation, all persons who are to use the dust extractor 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:
xInstallation
xStart-up
xOperation
xMaintenance and repair
The device must be used only by persons who have been instructed in its
handling and are explicitly authorized to use it.
Always keep the operating manual at the place where the suction device is being
used, so that it can be seen by personnel at all times.
No liquids, aggressive gases, easily flammable materials or glowing particles
(such as hot embers) may be aspirated. For example, it is prohibited to use the
DUSTOMAT in painting operations. It is forbidden to exhaust processing machines
with active ignition sparks or hot embers (such as multi-blade saws).
The dust extractor is intended only for dry cleaning and must not be used or stored
outdoors or under wet conditions.
Installation and operation in dust explosive zones or gas explosive zones is
not permitted.
OnlyoriginalESTAreplacementpartsmust be used; use of other products will
void the warranty.
During exhaust, the volume flow returned from the dust extractor into the room
must be no more than 50% of incoming air. With free room ventilation, the
incoming airflow must equal the room volume every hour. This means that the rate
of air replacement must be once per hour.
Incoming airflow [m!/h] = room volume [m!] air replacement rate [1/h]
Example:
When the ESTA dust extractor is operating at the nominal airflow volume of 720
m!/h, the same volume of fresh air must therefore be fed in. This occurs with
natural ventilation if the volume of the work room is 720 m!(e.g., 720 m"surface
with a 2.4 m ceiling height).

09201-52-01 DUSTOMAT --10 5
Make sure that the power cable does not become damaged by being run over,
compressed, pulled, etc.
The power cable must be examined regularly for signs of damage or ageing.
The device must not be used if damage to the power cable is determined.
The power cable and plug must be replaced only by an appropriately trained
electrical specialist.
For the power supply and the device’s power cords, only original ESTA
replacement parts must be used. This guarantees that they are spray-proof
according to applicable standards and have the necessary mechanical strength.
The power cord must be plugged in only after the dust extractor has been
successfully set up at its place of use. For this a 16-amp Schuko wall socket fuse
or a CEE wall socket with a slow-blow fuse must be in place.
Plugs and connectors complying with EN 61241-14 must be used for connecting
electrically driven industrial exhausts and dust extractors. Coupling plugs and
connectors or adapters are not permitted.
After use, before moving the device to another site and before cleaning,
maintenance, or replacement or removal of movable parts, the device must be
unplugged.
The DUSTOMAT is to be moved on a stable, even surface that can securely
support a weight of 350 kg.
To prevent dust release when transporting the device, the intake port must be
closed with the sealing plug.
Only original ESTA conductive accessories may be used for operating the
device.
From its first use, the device contains toxic dust. Emptying and
maintenance processes, including removal of the dust collection container,
must be performed by expert personnel who are wearing appropriate
protective gear. The device must not be operated without the complete
filtration system!

09201-52-01 DUSTOMAT-10 6
According to work equipment user directive 2009/104/EC, 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
immediately. Turn the device off with the emergency switch and pull the
plug. If there is a fire, the fire department is to be alerted immediately, and
the fire must be contained by appropriate means! A suitable extinguishing
agent must be kept near the device before start-up and during operation.
2. Preventing mechanical hazards
Allmovablemachinepartsdrivenbyelectric motors must be covered by fixed,
securely fastened protective covers that can be removed only with tools.
Residual risk:
If a covering that can only be unfastened with a tool is removed, there is risk
of injury if the machine is running!
3. Preventing electrical hazards
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 60 335.
Residual risk:
If a covering that can only be unfastened with a tool is removed, a hazard is
posed by electric current!
4. Preventing dust hazards
Usingaone-waydustcollectionbagwitha sealable opening guarantees low-dust
removal of the collected material.
Residual risk:
When emptying the dust collection bag, it is possible to inhale dust.
Following the instructions in the section “Disposing of collected dust
materials” will minimize this hazard!

09201-52-01 DUSTOMAT --10 7
5. Intended use
The ESTA dust extractor has been manufactured according to the state of the art
and in compliance with safety regulations. It is suitable for commercial use, such
as in industrial firms and workshops.
When used as intended, the devices are suitable for removing dry, non-
flammable, non-explosive, nontoxic dusts. They are equipped with a filter for dust
class “M” (moderate hazard) for separation of dust with an exposure limit of more
than 0.1 mg/m!. The purified air can be directed back into the work area.
When connecting the suction hose, make sure to use only electrically conductive
hoses and that the electrical connection between the hose and the port is perfect.
If a so-called “spiral hose” is used, the metal spirals must be stripped and pressed
to the bare wall of the exhaust port with a pipe clamp after the hose is attached.
Shavingsanddustcanbeextractedfromprocessing machines whose exhaust
port is up to 100 mm in diameter. If it is smaller than 100 mm, ESTA supplies a
corresponding reduced fitting, which is placed on the machine’s exhaust port as a
junction. Processing machines with exhaust port diameters larger than 100 mm
must not be connected to this device!
The device must not be used or stored outdoors or under wet conditions.
Only plugs and connectors complying with EN 61241-14 must be used for
connecting electrically driven industrial vacuums and dust extractors.
Extension cords, coupling devices and adapters are not permitted.
Other applications are considered unintended use. ESTA is not liable for damages
due to unintended use!
ESTAsetsupthedustextractoraccording to the operator’s information.

8 DUSTOMAT --10 09201-52-01
6. Technical data and description
6.1 DUSTOMAT-10
Model
(see model plate) 10WN 10DN
Max. airflow volume [m!/h] 720
Connection diameter [mm] 100
Max. vacuum [Pa] 2,800
Nominal flow volume [m!/h] 580
Vacuum at port [Pa] 2,600
Connection voltage [V] 230 400
Drive output [kW] 1.3 1.1
Rated current [A] 8 2.6
Nominal frequency [Hz] 50
Circuit breaker [A] 16
Filter area, dust class “M” [m"] 3.5
Dust collection container [litres] 100
Environmental conditions [°C] 5 d-d25
Max. air humidity [%] 60
Average sound pressure level Lpa* dB(A) 70
Dimensions (L x W x H) [mm] 1,165 x 530 x 1,636
Weight [kg] 65
Production year See model plate.
*= per DIN EN ISO 3744, measurement margin of error approx. 4 dB(A)
technical changes reserved

09201-52-01 DUSTOMAT -10 9
6.2 Functional description
Dependingontheoperatingconditions, the DUSTOMAT is equipped with a
1.3 kW AC motor or a 1.1 kW three-phase motor that drives a radial fan.
The main switch supplies or cuts off the necessary power to the device, and the
device is turned on and off with the green toggle switch on the AC version. The
three-phase current versions have a red-green double push button for this
purpose.
The vacuum created by the fan draws air through the suction hose connected to
the intake port. A permanent filter set up within the filter housing separates the
dust that is in the exhausted air.
The purified air is guided back into the room through the exhaust vents.
The DUSTOMAT is equipped with a manometer as a control device for overseeing
minimum airflow volume. This monitoring device measures the vacuum in the
filter. With increased dust soiling the filter, the flow resistance increases along with
the vacuum behind the filter. At the latest, the filter must be cleaned when the
zone designated for the intake diameter is reached on the manometer.
The filter is cleaned with manual equipment. The filter is freed from dust and
regenerated using a hand crank on the lid. The dust collection container with a
collection bag underneath the filter catches the dust that is cleared.
For easier removal of the collected material, the upper part can be tipped
backwards and the dust collection container removed from the device.

10 DUSTOMAT --10 09201-52-01
7. Delivery and commissioning
7.1Deliveryandtransport
Atdelivery,theDUSTOMATisfastenedtoapallet.Aftertheprotectivecoverand
the bottom fasteners have been removed, the device can be picked up with a
forklift. Do not use a crane!
Upon delivery, please inspect the device for transportation damage. Damage
determined must be reported and documented immediately.
ESTA customer service: [phone] - 0
When moving the device, make sure the ground can support it and be driven
over.
7.2Commissioning
Only persons authorized under “General safety instructions” must turn the
device on.
Before setting up the cable connection between the device and the power
grid, check to make sure the operating voltage shown on the model plate is
the same as that of the grid.
Before the device is used, its operation must be tested.
Thedevicehasared-greendoublepushbuttonfor
switching on and off.
ON switch
OFF switch

09201-52-01 DUSTOMAT -10 11
On type “DN”, the fan’s direction of rotation must be checked!
After turning on the device, make sure that the fan rotor’s direction of rotation is
correct.
For this purpose, look at the light underneath the double push button on the front
side. If this lights after the main switch is turned on, the direction of rotation is
wrong, and the power supply’s polarity must be reversed.
The polarity of the power feed must be changed only by an electrical
specialist. For this purpose, the CEE plug is equipped with a phase inverter.
Using a screwdriver to turn the pole pin built into the insulated part of the
plug changes the fan rotor’s direction of rotation.
When the direction of rotation is wrong, the device gets impermissibly hot,
the airflow volume gets weaker, and the device’s performance suffers. This
can also damage the device.
Onceafunctionalinspectionhasbeencompleted, the connection can be made to
the processing apparatus that is to be exhausted.
For this, the device must be turned back off, unplugged from the power grid, and
set on an even surface as close as possible to the workplace. Lock the device’s
wheels.
The dust extractor’s intake port has an interior diameter of 100 mm. At the port,
the suitable electrically conductive ESTA suction hose is inserted and secured
with the locking bolt. This suction hose comes with a plug connection attached.
Connection is made to a processing machine that has a smaller port diameter by
using an adaptor that fits the exhaust hose and is chosen to fit the port diameter of
the machine creating the dust. Here also, pay attention to the electrical
conductivity between the connections.
Now the device can be connected to the power grid again.
After connecting the suction hose to the processing machine, first set the
dust extractor in motion, and then the processing machine. When switching
off, follow the same procedure in reverse.
During operation, the dust extractor’s location should not be changed.
When the device is turned off, the neutral line is not disengaged. The device
is therefore intended only for use in TN networks.

12 DUSTOMAT -10 09201-52-01
8. Maintenance and troubleshooting
8.1 Maintenance instructions
For maintenance by qualified personnel, the device must be opened, cleaned and
inspected at the given locations, as well as possible, without any hazard being
posed to maintenance personnel or other persons. Proper precautions must be
taken before cleaning and removal of wearing parts. This includes locally filtered
forced-air ventilation in the area in which the device is being maintained, and
proper personal protective gear.
During maintenance or repair work, all soiled objects that can no longer be
adequately cleaned must be disposed of. Such objects must be discarded in an
impermeable bag in compliance with applicable regulations for disposal of such
refuse.
If the device is not needed in its location of use for a long time, it must be stored in
a dry room. The temperature should not be below 5°C or over 25°C.
Before the device is placed into storage, it is recommended that it be cleaned with
a disposable damp cloth, that the filter be cleaned, and that the dust container be
emptied.
The device must never be cleaned with flowing water.
The operator is obligated to have maintenance performed once per year.
During maintenance, the device is to be tested by a trained expert for
correct operation. A log is to be kept of the main annual inspection in the
included maintenance book. It must document the date of inspection,
deficiencies determined and the name of the inspector. The date of the next
inspection can be read from the test plate installed on the device.

09201-52-01 DUSTOMAT -10 13
8.2 Inspection and maintenance intervals
Regular maintenance consists of 3 intervals:
1. Daily inspection includes:
By the dust extractor’s user
Visualinspection
xfordamagetothedeviceoritsparts
x for mechanical damage to the power cable
x for a full dust collection container (regulations require that the container be
emptied if it is more than 2/3 full)
2. Monthly inspection includes:
By expert maintenance personnel
Visualandfunctionalinspection,
x for filter leaks (dust trails or deposits on the air outlets)
x whether function of the minimum airflow volume inspection (manometer) is
assured. During inspection, the device’s air intake must be closed. If the
display reaches the limit threshold, the equipment is working properly.
3. The main annual inspection includes:
ThelasttestbyESTAisdocumentedonthedevice!
In collaboration with the ESTA maintenance service
xFlow volume measurement
x Vacuum measurement
x Current consumption measurement
xVisualcheckoffilters
xSealinspection
After maintenance, the device receives a new test plate to document that
maintenance has been performed.
This inspection must be done once per year.
The maintenance work must be recorded in writing in the maintenance book
provided. This must make clear the equipment inspected and, if necessary,
the deficiencies found, along with the name of the inspector and the date of
the inspection.
If there is a malfunction, the dust extractor must be switched off
immediately and the responsible maintenance service notified.

14 DUSTOMAT -10 09201-52-01
According to work equipment user directive 2009/104/EC, safety devices for
prevention or removal of hazards must be regularly maintained and
regularly inspected by an expert for safe, flawless operation.
Maintenance must be performed according to accident prevention
regulations. The device must be disconnected from the power supply.
Get the most from ESTA’s maintenance service!
A maintenance contract ensures a long life and top-notch operation for your dust
extractor.
We’ll make you a great offer — just call us up:
ESTA maintenance service: [phone] - 0
ESTA replacement part service: [phone] - 0

09201-52-01 DUSTOMAT -10 15
8.3 Troubleshooting
Always use the following checklists if a malfunction is evident. Call the ESTA
maintenance service right away if there is a malfunction that is not discussed in
this list. Do not perform any repairs on the device yourself if they are not explicitly
specified.
Problem Possible cause Possible solution
Motor stalls / motor won’t
restart
Motor protection
triggered by frequently
turning the device on and
off
Let the device rest for
about half an hour; then
normal work with the
device can resume
Suction performance
diminishes /
or no suction
Filter clogged
Suction hose clogged
Clean filter
In a vacuumed area,
hold the hose vertically
and bang it out with a
rubber mallet.
Although the filter has
been cleaned, the
vacuum display on the
manometer stays at the
limit threshold of the
corresponding intake
diameter.
Fine dust is sucked right
back to the filter.
Dust collection container
too full
Filter pores clogged in
main filter
Clean several times with
device at rest and let the
dust settle (1 min.)
Replace dust collection
bag
Replace filter
If dust escapes or clouds up from the air outlets, if smoke develops or the
fan runs loudly, the device must be disconnected from the power
immediately!
When cleaning, the person doing the work must always wear a respirator
mask (filter mask with particle filter, filter class P3) and gloves.
Before opening the switch box, make sure to turn the main switch to the “0”
position and pull the electrical plug! Work in the switch box must be
performed only by an electrical expert or an appropriately trained person.

16 DUSTOMAT -10 09201-52-01
9. Monitoring the minimum volume flow
9.1 Dust extractor - operation
Withthedustextractor,shavingsanddust can be exhausted from processing
machines with various exhaust port diameters. In so doing, make sure that the
exhausted airflow volume does not drop below the lower limit. This minimum
airflow volume depends on the port diameter of the processing machine creating
the dust.
On the manometer’s scale, the minimum airflow volume for each port diameter is
marked in red. The vacuum must be monitored
manually. If, for example, a port diameter is 100 mm,
and the manometer’s needle is on the 100 mark, the
filter must be cleaned. This applies correspondingly
to exhaust ports of 80 mm and 63 mm diameters.
The relationships are shown in the accompanying
illustration and the following table.
1 2 3 4
dia. D (mm) V (m!/h) p1(mbar) p2(mbar)
63 224 27.4 28
80 362 26 27.5
100 565 22.2 25.7
Key to the columns:
Column 1: Diameter of the exhaust port on the processing machine.
Column 2: Minimum airflow volume at 20 m/sec. in the exhaust port.
Column 3: Possible vacuum at the beginning of the suction hose
(2.5 m long). - Interface between the dust producer and the
dust extractor at minimum airflow volume.
Column 4: Vacuum marked on the manometer scale.
A processing machine requiring greater suction volume than shown in the
chart cannot be properly exhausted with this dust extractor.

09201-52-01 DUSTOMAT -10 17
9.2 Industrial dust extractor - operation
During use as an industrial dust extractor, the minimum airflow volume is also
monitored with the manometer. ESTA supplies optional suction fittings with
diameters of 100 mm, 80 mm and 63 mm. For example, for a suction hose with a
diameter of 80 mm, the filter must be cleaned when the manometer’s needle is
below the “80 mm” point after the nozzle has been withdrawn. This applies
correspondingly to the other diameters.
10.Cleaning
The people assigned to cleaning work must be instructed on the aspirated
toxic materials and wear a breathing protection mask with a class P3
particle filter, as well as protective gloves. All distractions by uninvolved
persons must be prevented.
During cleaning work, all soiled objects that can no longer be adequately
cleaned must be disposed of. Such objects must be discarded in an
impermeable bag in compliance with applicable local regulations for
disposal of such refuse.
10.1 Cleaning the filter
When the device’s suction performance diminishes after every use, clean the filter
unit.
A safety device is built into the machine for
monitoring the minimum airflow volume to be
exhausted. A manometer shows the latest time for
cleaning (depending on the exhaust port diameter).
If the filter is to be cleaned, wait about one minute
after turning off the fan, to allow the fan’s rotor to
come to a standstill. For cleaning the filter, turn the
hand crank on the filter part about 60 times
rightward and then 60 times leftward. The cleaning
process should take about two minutes (1 minute
per rotation direction) and must be repeated three
times.
This process should be performed even after a long
downtime.
If fine dust is being exhausted, the filter needs to be cleaned more often.

18 DUSTOMAT -10 09201-52-01
Once cleaning has been performed, wait a short time and check the fill level
through the dust collection device’s inspection window. At the latest, empty the
dust collection container when the level has reached the upper edge of the
window (see the section on “Disposal”).
During operation, if the manometer display is still within the limit range, check to
see if the suction line is clogged.
If that is not the cause, the filter must be replaced.
10.2 Filter replacement
Filter replacement must be performed in a well-ventilated room or outdoors.
The people assigned to this work must be instructed on the aspirated toxic
materials and wear a breathing protection mask with a class P3 particle
filter, as well as protective gloves. All distractions by uninvolved persons
must be prevented.
Afteranextendedoperationperiod, the filter pores can be clogged by extremely
fine dust. Even the cleaning equipment cannot remove this dust. Now the affected
filter must be replaced with a new one.
If possible, filter replacement must be done when there is no work going on. Used
filters must be discarded in compliance with local regulations.
Before the filter is replaced, it must first be cleared of loose dust using the
available cleaning system, and the power must be cut off.
Removethecrankfromthecleaningdeviceinordertoloosenthethreaded
fastening pin. Now the crank can be pulled out. After that, loosen the clamping
ring that holds the cover plate and remove the cover plate.
Pull the dust collection bag over the upper part of the vacuum.
The upper part will now tilt backwards when the locking bolt is removed.
On the underside of the filter part, 6 nuts are visible (M8, SW 13); remove them.
Now the used filter can be pulled out of the upper part while being pulled upward
against the cleaning shaft. In this way, the dust collection bag turns over the entire
filter, so that no dangerous dust enters the environment. Close the dust collection
bag with the supplied band so that no dust can escape.
Install the new filter cartridge with the integrated cleaning equipment by
performing the same process in reverse. Additionally, the filter cartridge must be
sealed at the upper side with sealing compound.
Cleaning the filter cartridge in a dismantled state by blowing it out or
beating it is not permissible!