Esta DUSTOMAT-160 S User manual

Operating manual
DUSTOMAT-160 S
DUSTOMAT-160 S
Art no.:
74020
DUSTOMAT-160 S
Art no.:
74021
Do not use this product unless you have read and
understood the assembly instructions beforehand.
Translation of the original operating instructions
74020-08-00

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DUSTOMAT-160 S
74020-52-00
Legal notice
Translation of the original operating instructions
Document no.: 74020-08-04
Publishing date: 16 April 2021
Device type: Mobile dust extractor DUSTOMAT-160 S
Item no.: 74.020 and 74.021
Document history
Version
Date
Change
00
16 April 2021
Document based on template 09506-08-04, texts adapted according
to schematic 08-02-00
Issued by
ESTA Apparatebau GmbH & Co. KG Tel.: [phone] - 0
Gotenstr. 2-6 Fax: [phone] - 500
89250 Senden, Germany E-mail: inf[email protected]
Germany Web: www.esta.com
Copyright notice per DIN ISO 16016
The transfer and reproduction of this document, or the use or communication of its content, is forbidden
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 operating instructions.
• Verifiable compliance with the prescribed maintenance intervals.
• Operation of the product with conveyed media having the specified chemical and physical proper-
ties.
• 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 writ-
ten approval of the manufacturer.

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Contents
Contents..................................................................................................................................................3
1. General instructions........................................................................................................................5
1.1 General notes prior to use ..........................................................................................................5
1.2 Legal issues ...............................................................................................................................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.............................................................................6
2. Product identification......................................................................................................................7
2.1 Intended use ..............................................................................................................................7
2.2 Improper use ..............................................................................................................................7
2.3 Foreseeable misuse ...................................................................................................................8
2.4 Warranty conditions....................................................................................................................8
2.5 Important information on the product..........................................................................................8
3. Safety ...............................................................................................................................................9
3.1 Symbols and labels used............................................................................................................9
3.2 Fire hazard prevention ...............................................................................................................9
3.3 Preventing electrical hazards .....................................................................................................9
3.4 Preventing mechanical hazards................................................................................................10
3.5 Preventing dust hazards...........................................................................................................10
3.6 Workplace ventilation ...............................................................................................................11
3.7 Product safety ..........................................................................................................................11
3.8 Qualified personnel ..................................................................................................................12
4. Structure and function ..................................................................................................................13
4.1 Representation.........................................................................................................................13
4.2 Functional description ..............................................................................................................14
4.3 Thorough electrical conductivity ...............................................................................................14
5. Transport and installation.............................................................................................................15
5.1 Transport..................................................................................................................................15
5.2 Set-up ......................................................................................................................................16
6. Commissioning..............................................................................................................................17
6.1. Electrical connection ................................................................................................................17
6.2 Connection ...............................................................................................................................18
6.3 Operating and display elements ...............................................................................................18
6.4 Rotation direction monitoring....................................................................................................19
7. Servicing & maintenance ..............................................................................................................20
7.1 Operating and auxiliary materials .............................................................................................21
7.2 Inspection and maintenance intervals.......................................................................................22
7.3 Changing the filter ....................................................................................................................23
7.4 Changing the paper bag...........................................................................................................23
7.5 Monitoring the minimum air volume flow...................................................................................24
7.6 Checking conductivity...............................................................................................................24
8. Faults and Rectification ................................................................................................................25
9. Decommissioning and disposal ...................................................................................................26
9.1 Decommissioning .....................................................................................................................26
9.2 Storage ....................................................................................................................................26
9.3 Disposal ...................................................................................................................................27
10. Technical data................................................................................................................................28
11. Optional equipment.......................................................................................................................29
11.1 Start-up with potential-free contact........................................................................................29
11.2 Extraction arm.......................................................................................................................30
11.3 Floor cleaning set .................................................................................................................30
11.4 Pre-separator........................................................................................................................31

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11.5 Throttle valve ........................................................................................................................32
11.6 Discharge air collection.........................................................................................................32
12. EC - / EU - Declaration of conformity ..........................................................................................33
Notes .....................................................................................................................................................34
Notes .....................................................................................................................................................35

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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 current operating
manual.
1.2 Legal issues
The product's design and construction meets the directives and standards of the Declara-
tion of Incorporation (According to MRL 2
006/42/EC, Annex II Par 1 B) to minimise any
possible potential risks originating from the product. 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

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1.4 How to read this document
This document is a component of the product it describes. Keep the instructions 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.). Prerequisite for safe work and trouble-free
handling is that all relevant information, 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-operator apply in addition to this doc-
ument.
The document also contains graphical examples along with the descriptions. The equip-
ment may differ somewhat from the descriptions and representations
1.5 Form and significance of warning information
DANGER
High risk of severe damage
indicates an imminent hazard. If this is not averted, death or very serious injury will result
WARNING
Moderate risk of severe damage
indicates the possibility of an imminent hazard. If this is not averted, death or very serious
injury may result.
CAUTION
Risk with minor damage
indicates the possibility of an imminent hazard. If this is not averted, slight or minimal inju-
ry may result.
NOTE
Material damage
Foreseeable material damage for the product and environment with a failure 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 occurs, and actions for averting
it.

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2. Product identification
2.1 Intended use
The product was designed for use at the following workplaces:
•Individual work station
•Group work station
•Rooms with several work stations
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 appropriately and as follows:
•For commercial use, such as in industrial enterprises and workshops
•For the extraction of dry, sticky and long-fibre dust
•For the extraction of non-flammable dust
•Only for dry cleaning.
Other applications or ones extending beyond these are considered to be improper use.
ESTA shall not be liable for damages due to unintended use.
The manufacturer sets up the product according to the operator’s information.
2.2 Improper use
The product may only be used within the scope of the technical data specified 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
•Change in the location during operation
•Use in dust or gas EXPLOSION areas
•Connecting to processing machines that may produce active ignition sparks or hot
embers
•Extraction of corrosive gases
•Extraction of highly flammable or glowing particles
•Extraction of moist or fluid substances
•Installation in paint shops
•Installation in food operations

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2.3 Foreseeable misuse
The use of the product in an unintended way, but which can arise from easily foreseeable
human behaviour.
This includes:
•Outdoor installation without suitable on-site measures
•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 attached parts (e.g.,
pipeline)
•Intake of items not suitable for suction (e.g., mobile phone, tool, glove, screws, etc.)
•Closing of intake opening
2.4 Warranty conditions
ESTA accepts no liability for damages and consequential damages to products or for per-
sonal injuries if the product is not used for its intended purpose. The operating company
must prove that the fault was not caused by inappropriate installation, assembly, mainte-
nance or use of the product.
For your own safety, use only genuine replacement parts and accessories. If other prod-
ucts are used, ESTA shall be released from any liability for resulting damage.
2.5 Important information on the product
Responsibility must be clearly stipulated for the following tasks:
•Transport
•Installation
•Commissioning
•Operation
•Maintenance and repair
•Cleaning
•Decommissioning
•Disposal

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3.Safety
3.1 Symbols and labels used
ESTA maintenance stickers show when and by whom the last maintenance was carried
out and when maintenance is next planned by the ESTA maintenance service.
3.2 Fire hazard prevention
DANGER
Danger of fire due to sparks and glowing particles
Severe injury including death possible
•Keep combustible, flammable materials away from the work area.
•Never run away if clothing catches fire. Extinguish flames by rolling on the ground or
by smothering them with blankets.
•If there is a fire, alert the fire department immediately, and contain the fire by appro-
priate means.
•
Keep a suitable extinguishing agent (not included in scope of delivery) near the
product before start-up and during operation.
•
A corresponding fire protection concept must be created by the operating company.
3.3 Preventing electrical hazards
DANGER
Electric shock from high voltage
Severe injury including death possible
•Any work on the electrical grid and on live components may only be performed by an
electrician.
•Follow the safety rules for working on electrical products.
•Shut down the product or any live components at the main switch before working on
them and secure them against reactivation (e.g. padlock).
•Establish electrical connections of the components according to the manufacturer's
specifications.
•Regularly check the power cable for damage and wear.
•Keep covers closed during operation.
•Do not switch on the product if it or the power supply exhibits visible damage and
secure it against reactivation (e.g. padlock).
•Have any damaged cable replaced by specialised staff.
After use, before moving the product to another site, and before cleaning, maintenance,
or replacement or removal of movable parts, switch off the product at the main switch and
secure it from reactivation (e.g. padlock).

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3.4 Preventing mechanical hazards
DANGER
Risk of injury posed by the drawing-in or entanglement of hair or loose items (e.g. chains,
hair, ties, etc.)
•Observe the safety regulations for work on products with rotating parts.
•Before working on the product, turn it off and secure it against unintentional reactiva-
tion.
•When working on the product, tie back long hair or wear a hairnet.
•When working on the product, do not wear any loose items (chains, ties).
WARNING
Danger of crushing due to loose or open covers
Injuries to limbs
•Keep covers tightly closed during operation.
•Ensure that inspection doors are firmly closed.
•Check regularly that fastening screws and component connections are secure.
•Only start up the product after the assembly is complete and correct.
•Watch out for pipe or hose connections and other valves, or disconnect if required.
All movable machine parts driven by electric motors must be covered by fixed, securely
fastened protective covers that can only be removed with tools.
3.5 Preventing dust hazards
CAUTION
Toxic dusts
Short-term impairment of the respiratory organs during inhalation
•Maintenance, cleaning, repair, and emptying work may only be completed by expert
personnel.
•Wear personal protective equipment.
•Ensure that the collection container is attached to the discharge opening.
•Ensure that inspection doors are firmly closed.
•Always complete all maintenance and upkeep work in a well-ventilated room.
•Seal the intake port with a sealing plug so it is dust-tight during transportation.
CAUTION
Dust deposits in the pipe system
Short-term impairment of the respiratory organs during inhalation
•Check the connected piping system regularly for dust deposits.
•Observe the minimum air speed required for use and the resulting minimum airflow
volume.

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When opening and emptying the collection container, dust inhalation cannot be ruled out.
That is why all servicing, cleaning and maintenance procedures, including the emptying
of the collection container, are only to be performed by specialist personnel with personal
protective equipment.
Personnel assigned to cleaning work must be instructed about the aspirated toxic materi-
als. Harm to bystanders and the environment must be prevented by all means. After the
maintenance has been carried out, the maintenance area must be thoroughly cleaned.
3.6 Workplace ventilation
The provisions of DGUV rule 109-002 must be complied with.
The operator must take air conditioning measures to ensure that the workplace ventilation
requirements are met.
3.7 Product safety
The following points must be considered to avoid injuries and other risks due to inappro-
priate use and operation of the product:
•Assembly, electrical connection, maintenance, initial operation, cleaning, repair and
other work in connection with the product may only be performed by trained special-
ists.
•The product must be checked for faulty or damaged supply lines (cables, pipe sys-
tems, etc.), connections and open system parts (inspection door, discharge open-
ing). 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 inspec-
tion 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 inspection doors are
opened that the product is disconnected from the power supply and secured against
unauthorised reactivation.
•Connect the product to the electrical power supply properly and in precise compli-
ance with the safety instructions and use it exclusively in accordance with the speci-
fications.
•In all emergencies, the product must be disconnected immediately from the power
supply, turned off at the main switch and the plug pulled immediately.

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3.8 Qualified personnel
Trained personnel
Trained personnel are those who have been instructed in the correct handling of the prod-
uct 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
Assembly personnel
Installation
Trained skilled
worker
Commissioning
personnel
Commissioning
Trained skilled
worker
Operating personnel
Operation
Qualified semi-
skilled
technicians
Maintenance personnel
Inspection
Maintenance
Repair work
Trained skilled
worker
Maintenance, cleaning
personnel
Maintain
Cleaning
Trained personnel
Electrical specialist
Troubleshooting
Trained skilled
worker

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4. Structure and function
4.1 Representation
1
Suction opening
port for the suction valves
4
Fan housing with air outlets
2
Removable maintenance cover for
filter change
5
Operating and display elements
3
Mobile dust collection container for
detachment
6
Clean air outlet to the fan
1
2
4
6
3
5

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4.2 Functional description
The DUSTOMAT-S is equipped with a three-phase motor which drives a radial fan.
The vacuum created by the fan sucks in air via the suction hose connected to the intake
port.
A permanent filter (cotton filter bag with an upstream paper bag) separates the dust from
the air. The purified air is guided back into the room through the exhaust slots.
The product is equipped with a manometer as a control device for minimum flow volume.
This control device measures the vacuum developing after the filter. The flow resistance
increases with increased filter soiling from the dust and with it, the vacuum after the filter.
The paper filter must be replaced if the area marked for the suction diameter on the
manometer is reached at the latest.
To dispose of the filled dust collection bag, the upper part can be lifted upwards and the
dust collection bag removed from the device.
4.3 Thorough electrical conductivity
A continuous electrical connection of all easily touchable metal parts which are not a com-
ponent of the electrical operating circuit (thus inactive) is established to earth. Prevents a
high contact voltage on electrically conductive device parts (e.g. housings) in the event of
a fault.

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5. Transport and installation
5.1 Transport
DANGER
Risk of falling and tripping
Danger to life from falling objects or loads
•Do not stand under suspended loads.
•Secure the assembly area and mark it out (e.g., with barrier tape).
•Always lift the product vertically during loading and assembly work.
•Only transport
the product with suitable, approved means of lifting and
transport.
•Do not place the product on a sloping surface.
•Wear personal protective equipment.
•Observe the local accident prevention regulations.
WARNING
Crushing hazard when setting the product down
Injuries to the hands and feet
•Secure the product against tipping and falling during transport.
•Set the product down carefully and cautiously during set-up.
•Wear work gloves and safety shoes.
NOTE
Material damage due to improper transport
Damage to the housing, lines and product components
•Do not push or pull the product across the floor if it does not have any rollers.
•Seal the intake port with a sealing plug so it is dust-tight during transportation.
•Pay attention to any protruding components when setting down the product.
•Note the centre of gravity (which is not in the centre) when setting down the prod-
uct.
•Make sure that the surface can be driven on, is level and sufficiently load bearing.
The product is delivered fastened to a pallet. Following removal of the protective covers
and the floor fixing, the device can be lifted using a forklift truck.
Do not use a crane.
1. Remove the packaging and check the product for damage and completeness
2. The product must not be put into operation if there is damage, or if the delivery is in-
complete. Contact ESTA in such cases
3. Any foreign objects inside the product must be removed before start-up.

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5.2 Set-up
NOTE
Damage to property and the environment
Observe minimum load-bearing capacity of the substrate
•Only install the product on a level, firm substrate with sufficient load-bearing capaci-
ty.
•Products that are stationary during use must be fastened to the floor with anchors or
another appropriate means of fastening.
NOTE
Avoid material damage due to electrostatic charge
The operator must ensure that conductive extraction systems and conductive processing
machines that are not earthed via the product are earthed on site and integrated in the
building’s equipotential bonding.
1. Lift the product from the pallet using a forklift at the positions provided and set it
down right next to the pallet.
2. Connect the product with the processing machine and extraction device.
3. The product is ready for further connection.

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6. Commissioning
WARNING
Danger of crushing due to loose or open covers
Injuries to the limbs
•Keep covers tightly closed during operation.
•Ensure that inspection doors are firmly closed.
•Check regularly that fastening screws and component connections are
secure.
•Only start up the product after the assembly is complete and correct.
•Watch out for pipe or hose connections and other valves, or disconnect if
required.
NOTE
Avoid material damage due to electrostatic charge
The operator must ensure that conductive extraction systems and conductive processing
machines that are not earthed via the product are earthed on site and integrated in the
building’s equipotential bonding.
NOTE
Material damage
•Inspect the product before each use for faulty, damaged or missing components.
•If there is damage, do not use the product and immediately notify the maintenance
personnel responsible.
6.1. Electrical connection
DANGER
Electric shock from high voltage
Severe injury including death possible
•Follow the safety rules for working on electrical products.
•
Secure the main switch against reactivation with a padlock when working on the
product.
•All work on the electrical mains and on live parts must only be performed by an elec-
trician.
NOTE
Observe rating plate
Before establishing cable connections between the product and the mains, check wheth-
er the operating voltage specified on the rating plate matches that of the mains.
The connection to the building’s power supply is established at the installation location by
the customer.
The mains plug may only be plugged in after the product has been set up in its installation
location:
•Schuko standard wall socket 16 amp. slow

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6.2 Connection
The product is set up with a connecting piece (reducer, muffle, etc.) with drill hole.
As a result, the connection piece is locked via a locking bolt. The drill hole must
be in line with the locking bolt position.
The appropriate, electro-conductive ESTA suction hose fixed to a connector is inserted
into the port and locked with the locking bolt.
The connection is made to a processing machine that has a smaller port diameter by us-
ing a reducer that fits the extraction hose and is chosen to fit the port diameter of the ma-
chine creating the dust. Pay attention to the electrical conductivity between the connec-
tions.
After connecting the suction hose to the processing machine, the dust extractor is started
first, then the processing machine. When switching off, this sequence must be performed
in reverse.
6.3 Operating and display elements
Main switch
Main switch for turning the product on and off. EMERGENCY-OFF switch, which can be
secured with a lock against unintentional activation.
Extraction ON/OFF
Extraction is started/stopped on the control panel by means of the On/Off switch.
Rotating field control
The rotating field control light illuminates when the system is started, if the rotational direc-
tion of the fan is incorrect.
Manometer
The minimum volume flow is monitored via the manometer. The red marking on the scale
shows when the maximum value of the minimum volume flow is reached.

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6.4 Rotation direction monitoring
DANGER
Electric shock from high voltage
Severe injury including death possible
•Follow the safety rules for working on electrical products.
•
Secure the main switch against reactivation with a padlock when working on the
product.
•All work on the electrical mains and on live parts must only be performed by an elec-
trician.
NOTE
Possible material damage caused by incorrect fan rotation direction
If the rotation direction is incorrect, the product heats up unacceptably.
The volume increases, the airflow volume falls, and the product’s suction performance
deteriorates.
Damage to the product cannot be ruled out.
After first switching on the product, the fan impeller’s direction of rotation must be
checked.
1. Turn the product off at the main switch.
2. Compare the rotation speed of the fan impeller with the rotation direction arrow on
the housing.
- If the motor fan wheel is turning in the wrong direction, the motor must have its
electrical polarity reversed.
3. Turn the product off at the main switch.
4. Have the phases of the phase reversing connector transposed by an electrical tech-
nician.
5. Switch on the product at the main switch.
⇨The product is ready for operation.

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7. Servicing & maintenance
DANGER
Electric shock from high voltage
Severe injury including death possible
•Any work on the electrical grid and on live components may only be performed by
an electrician.
•Follow the safety rules for working on electrical products.
•
Secure the main switch against reactivation with a padlock when working on the
product.
•Before working on the product, disconnect it from the voltage supply.
WARNING
Danger of crushing due to loose or open covers
Injuries to the limbs
•Observe the local accident prevention regulations.
•Only empty the collection container when the system is switched off.
CAUTION
Toxic dusts
Short-term impairment of the respiratory organs during inhalation
•Maintenance, cleaning, repair, and emptying work may only be completed by expert
personnel.
•Wear personal protective equipment.
•Ensure that the collection container is attached to the discharge opening.
•Ensure that inspection doors are firmly closed.
•Always complete all maintenance and upkeep work in a well-ventilated room.
•Seal the intake port with a sealing plug so it is dust-tight during transportation.
All 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.
All maintenance tasks should be carefully performed within the given time-scales. Preven-
tative maintenance of the components prolongs the life of the product. So does regular
cleaning and preventative exchange of wearing parts.
Safety devices for prevention or removal of
hazards (e.g. according to the 2009/104/EC
work equipment user devices and TRGS 560) must be regularly maintained and inspected
by an expert for safe and appropriate operation.
Shut down the product immediately if malfunctions and defects are discovered and notify
the responsible maintenance and repair staff.