Esta DUSTOMAT 4 ATEX User manual

DUSTOMAT 4 – ATEX
Mobile Dust Extractors
The World of Extraction
OPERATING INSTRUCTIONS

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
DUSTOMAT 4 ATEX
Non-Conductive Dusts
DUSTOMAT 4-10 ATEX
Order no
09.732
DUSTOMAT 4-24 ATEX
Order no
09.762
and variations
Do not use this device unless you have
read the operating instructions and understood them.
Translation of the original operating instructions
09732-08-01

2
DUSTOMAT 4 ATEX
09732-52-01
Edition notice
Translation of the original operating instructions
Document no.: 09732-08-01
Publishing date: 07.05.2018
Type of device: DUSTOMAT 4 ATEX
Article no.: 09.732 // 09.762 and versions
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 16016:2017-08)
Transfer or reproduction of this document, or the use or communication of its content, is forbid-
den without explicit consent. Violators will be liable for damages. All rights to patent, utility or
design registration are reserved.

Contents
09732-52-01
DUSTOMAT 4 ATEX
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 Illustration of the DUSTOMAT 4 ATEX device ....................................................... 10
3.2 Functional description ............................................................................................ 11
3.3 Minimum volume flow monitoring ...........................................................................11
4Safety.........................................................................................................................................12
4.1 Hazard categories .................................................................................................. 12
4.2 Symbol explanation ................................................................................................12
4.3 General safety instructions .....................................................................................14
4.4. Fire hazard prevention......................................................................................... 14
4.4 Preventing mechanical hazards .............................................................................15
4.5 ATEX hazard prevention ........................................................................................16
4.6 Preventing electrical hazards .................................................................................17
4.7 Preventing dust hazards.........................................................................................18
4.8 Preventing noise hazards.......................................................................................19
5Delivery and commissioning....................................................................................................20
5.1 Delivery and transport ............................................................................................20
5.2 Connection ............................................................................................................. 21
5.3 Function check ....................................................................................................... 24
5.4 Commissioning....................................................................................................... 26
5.5 Troubleshooting during commissioning ..................................................................28
6Operating instructions..............................................................................................................29
6.1 Control panel of the ESTA control system (standard) ............................................29
6.2 Operating the device ..............................................................................................30
6.3 Jet pulse cleaning...................................................................................................31
7Maintenance & troubleshooting...............................................................................................33
7.1 Maintenance instructions........................................................................................33
7.2 Inspection and maintenance intervals ....................................................................35
7.3 Detaching the filter mat outlet element ................................................................... 37
7.4 Clean the air guide plate ........................................................................................38
7.5 Replacing the control filter...................................................................................... 41
7.6 Replacing filter cartridges ...................................................................................41
7.7 Policing filter as a secondary filter cassette (dust class H) ............................. 43
7.8 Eliminate faults.....................................................................................................45
7.9 Setting the minimum airflow volume monitoring .....................................................47
7.10 Clean the device ................................................................................................... 48
7.11 Store the device.................................................................................................... 48
8Disposal.....................................................................................................................................49
8.1 Disposal of the device .........................................................................................49
9Optional equipment ..................................................................................................................50
10 EC-/EU-Declaration of Conformity ...........................................................................................51
11 Special conditions for the user ................................................................................................52
11.1 Zone classification..................................................................................................52

ContentsContents
54
DUSTOMAT 4 ATEX
09732-52-01
11.2 General notes for the user......................................................................................52
11.3 Special notes for the user.......................................................................................53
Notes.................................................................................................................................................54
Notes.................................................................................................................................................55

General instructions
09732-52-01
DUSTOMAT 4 ATEX
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 operat-
ing personnel
Basic knowledge of
the extraction pro-
cess and the ex-
tracted material
- Hearing protection
- Safety shoes
- Safety helmet
- Work gloves
Troubleshooting
Electrical spe-
cialist
Technical training
with knowledge and
experience for iden-
tifying and prevent-
ing hazards posed
by electricity
Servicing /
Cleaning
Trained cleaning
personnel
Essential knowledge
of the extracted ma-
terials and how
these should be
handled in accord-
ance with local regu-
lations
- Hearing protection
- Safety shoes
- Work gloves
-Particle filter masks
Maintenance
Trained mainte-
nance personnel
Electrical spe-
cialist
Technical training
with knowledge and
experience for iden-
tifying and prevent-
ing hazards posed
by electricity
- Safety shoes
- Hearing protection
- Work gloves

General
instructionsGeneral
instructions
54
DUSTOMAT 4 ATEX
09732-52-01
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 de-
vice 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 estab-
lished 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 han-
dling 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.

Product identification
09732-52-01
DUSTOMAT 4 ATEX
7
2 Product identification
2.1 Technical Data
We reserve the right to make technical changes.
Item no.
09732
09762
Model DUSTOMAT 4
4-10
4-24
Drive power
[kW]
2,2
4,0
Connection voltage
[V]
400
Nominal frequency
[Hz]
50
60
50
60
Nominal current
[A]
7,8
7,6
Circuit breaker
[A]
C16A (Automat)
Protection class
IP 54
Max. vacuum
[Pa]
2.500
3.600
Max. volume flow
[m³/h]
2.000
3.250
Filter type
Filterpatrone Filterklasse M
Collection drawer
[l]
42-50
Disponal carton (38 Liter)
[Stck.]
2
Average sound pressure level LpA*
[dBA]
68
71
Suction-socket ø
[mm]
125
140
160
180
200***
Dimensions L x W x H
(including filter unit)
[mm]
1.460 x 935 x 1.440
1.660 x 950 x 1.630
Total weight (including filter unit)
[kg]
ca. 260
ca. 310
Production year
siehe Typenschild
Ambient temperature
[°C]
540
Rel. humidity
[%]
30 - 70
Min. spatial requirement around the
device
Operator's side (front)
Inlet
Outlet
Rear
Top
[mm]
1.000
1.000
1.000
500
1.000
Ambient temperature
[°C]
540
* 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
54
DUSTOMAT 4 ATEX
09732-52-01
2.2 Intended application
2.2.1 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:
As a fan unit of a modular dust extraction concept.
For commercial use, such as in industrial enterprises and workshops.
For the extraction of non-conductive dusts in individual work areas in Zone
22.
For the separation of dry, free-flowing, flammable, explosive and non-
conductive dust-air mixtures in dust-explosive zone 22 (see BetrSichV
[German Ordinance on Industrial Health and Safety], Annex 3).
Only for installation on conductive foundation or breccia (e.g. rock, con-
crete, wood).
Only for dry cleaning.
As a central extraction system on dust-generating machinery.
As a central extraction system on chip-generating machinery.
Only in combination with electrically conductive pipe or hose lines.
Other applications are considered unintended use. ESTA is not liable for damages
due to unintended use!
2.2.2 Improper use
The device has been manufactured according to the state of the art and recog-
nized safety regulations. Unintended use may cause hazards.
Therefore:
Do not use or store outdoors or in wet conditions.
Do not change the location of the device during suction operation.
Not for the extraction of dusts with a known low minimum ignition energy
(MIE <10mJ).
Do not set up or operate in dust-explosive zones 20 and 21.
Do not set up or operate in gas-explosive zones.
Do not suck in or extract explosive or equivalent materials in the sense of
§ 1 of the Sprengstoffgesetz [German Explosives Act], of liquids, or of mix-
tures of flammable dusts with liquids.
Do not suck up dust sources for which suction connection is larger than
that of the device.
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.
Do not suck up any readily flammable or glowing particles.

Product identification
09732-52-01
DUSTOMAT 4 ATEX
9
2.2.3 Reasonably foreseeable misuse
Intake of glowing embers such as, e.g., cigarettes
Intake of items not suitable for suction (e.g., mobile phone, tool, glove,
screws, etc.)
Unauthorised modifications to the product
Closing the intake opening

Product Description
54
DUSTOMAT 4 ATEX
09732-52-01
3 Product Description
3.1 Illustration of the DUSTOMAT 4 ATEX device
Outlet element
clean air
Compressed air tank
Jet pulse cleaning
Inspection chan-
ber air guide plate
Jet pulse cleaning
Filter unit
Fan Unit
Disposal unit
Intake port
Lifting device
Control unit

Product Description
09732-52-01
DUSTOMAT 4 ATEX
11
3.2 Functional description
The fan unit can be combined with different filter units from the DUSTOMAT 4 se-
ries. It is equipped with a three-phase motor which drives a radial fan. The device is
supplied with or disconnected from the requisite power via a main switch. The fan is
turned on and off via the control panel.
Due to the negative pressure produced by the fan, air is sucked in through the cor-
responding filter unit. Permanent filters located in the filter unit separate the dust
contained in the air which is sucked in. The purified air is guided back into the room
through the outlets on the top of the fan unit.
The device is fitted with a pre-separator / air guide plate. This pre-separator / air
guide plate is installed behind the intake connection piece, which pre-separates
coarse particles and thus prevents these coarse particles being sucked against the
filter.
The control unit is integrated within the fan unit. The control unit monitors the vol-
ume 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 will be indicated by a
message in the text field of the control panel. At the same time, the filter cartridges
are cleaned automatically with compressed air. A pneumatic jet pulse cleaning de-
vice is integrated within the device's filter unit for this very purpose. The filters are
freed from dust and regenerated 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, a disposal carton can be in-
serted into the collection draw which is disposed of together with the collected ma-
terial.
3.3 Minimum volume flow monitoring
Extraction elements with various intake connection piece diameters can be oper-
ated with the device. When so doing, you must ensure that
The minimum airflow volume sucked away is not undershot.
- The minimum airflow volume depends on the diameter of the intake
connection piece of the extraction element and the requisite convey-
ing velocity.

Safety
54
DUSTOMAT 4 ATEX
09732-52-01
4 Safety
4.1 Hazard categories
Safety instructions and cross-topic information are indicated in this manual by
symbols. Based on the severity of the hazard, the hazard warnings are catego-
rized as follows:
DANGER
Warning and safety notices for ATEX devices and protection systems for a recog-
nised danger.
Failure to comply can lead to severe injury or death, and can destroy the device or
parts thereof.
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
Information on possible damage to the product and the environment.
Non-observance may cause material damage.
4.2 Symbol explanation
Further ATEX information
Further information
Reference to ESTA customer service
Reference to legal regulations

Safety
09732-52-01
DUSTOMAT 4 ATEX
13
4.2.1 Symbols on the device
Before commissioning, read and observe the operating instructions and safety
instructions (per ISO 11684)
1. Switch off the product.
2. Wait 5 minutes.
3. Then pull out the collection drawer or open
the product
Do not take in glowing dust or other sources of ignition. Do not use in conjunc-
tion with spark-generating machinery.
Suitable for connection to dust-producing machinery in Zone 22. One must en-
sure that no sources of ignition are picked up.
The control cabinet must not be opened while it is located in an explosive at-
mosphere.
Do not open in an
explosive atmosphere!

Safety
54
DUSTOMAT 4 ATEX
09732-52-01
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 im-
mediately, turned off at the main switch and the plug pulled immediately.
4.4. Fire hazard prevention
DANGER
Danger of fire due to sparks and glowing particles
If there is a fire, alert the fire department immediately, and contain the fire
by appropriate means.
Keep a suitable extinguishing agent near the product before start-up and
during operation.
A cyclone can separate sparks and glowing particles but the manufacturer does
not guarantee any protection from fire as a result. Spark detection and quenching
systems adapted to the application can be provided for this.

Safety
09732-52-01
DUSTOMAT 4 ATEX
15
4.4 Preventing mechanical hazards
WARNING
Crushing hazard
Make sure that the surface can be driven on, is level and sufficiently load
bearing.
Always wear safety shoes when moving the device!
Keep covers tightly closed during operation
Do not place on a sloping floor!
Always engage the castor locks when parking the device!
Look out for pipe and hose connections and other valves when moving the
device. Detach if necessary.
WARNING
Risk of falling and tripping
Always pay attention to the local accident prevention regulations.
Keep a distance from the device when you are not working with it.
Always push the collection drawer back in after visual inspection and empty-
ing.
The lifting device protrudes from the device when at rest.
Do not stand on the lifting device.
All movable machine parts driven by electric motors must be covered by fixed, se-
curely fastened protective covers that can be removed only with tools.

Safety
54
DUSTOMAT 4 ATEX
09732-52-01
4.5 ATEX hazard prevention
DANGER
Risk of explosion from the intake of sources of ignition
Ensure that no ignition sources can be sucked in.
Do not connect to processing machines that may produce active ignition
sparks or hot embers.
DANGER
Risk of explosion from installing and operating in a prohibited zone
Installation and operation is only permitted in dust-explosion zone 22!
Installation and operation in dust-explosion zones 20 and 21 is prohibited!
Installation and operation in gas-explosion zones is prohibited!
DANGER
Risk of explosion due to use of unauthorised spare and accessory parts
Only use original ESTA spare parts and plug devices in line with DIN EN
60079-14.
Do not use any extension lines, coupling plug devices or adapters.
The operator is to ensure that conductible extraction systems (e.g. extrac-
tion hood and pipe line) and conductible processing machine (e.g. devices
of protection class II), which are not earthed via the device, are earthed in a
different fashion.
DANGER
Risk of explosion from opening the control cabinet in an explosive zone.
Only open control cabinet outside of explosion zones.
DANGER
Risk of explosion from opening the device in an explosive zone.
Perform maintenance, cleaning and servicing work for which the device
must be opened in a well-ventilated room or install locally filtered forced-air
ventilation in this area.
In the event of maintenance, cleaning and servicing work for which the de-
vice must be opened, only use tools and wear protective clothing (ESD)
that are suitable for the zone.
DANGER
Risk of explosion from working on the device with tools that are not permitted
In the event of maintenance, cleaning and servicing work, only use tools
and wear protective clothing (ESD) that are suitable for the zone.
In a raw gas zone, one must assume zone 21 while the device is in operation. The
device is designed for this operation.

Safety
09732-52-01
DUSTOMAT 4 ATEX
17
4.6 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
Render the device voltage-free by pulling the mains connector
Any work on the electrical grid and on voltage-conducting parts may only
be performed by an electrical specialist.
Do not damage by running over, crushing, straining, etc.
Regularly check the power cable for damage and ageing.
Do not use if damage has been found on the power cable!
Keep covers closed during operation
The device must be secured from being switched on again while work is
being carried out on it.
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 system at the
main switch and pull the mains connector.

Safety
54
DUSTOMAT 4 ATEX
09732-52-01
4.7 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.
Seal the intake port with a sealing plug so it is dust-tight when transporting.
CAUTION
Damage due to dust build-up in the pipe system
Check the connected piping system regularly for dust deposits.
Observe the minimum air speed required for your application and the re-
sulting minimum airflow volume.
When removing the dust collection carton 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.