Esta VACUMAT 1000 User manual

Operating Instructions
VACUMAT
Fan Unit
VACUMAT 1000 (order no.: 07100)
VACUMAT 2200 (order no.: 07220)
and variations
Do not use this product unless you have
read the operating instructions and understood them.
Original operating instructions
07220-08-03

Edition notice
Original operating instructions
Document no.: 07220-08-03
Publishing date: 04/10/2016
Model: VACUMAT fan unit
Article no.: 07100 // 07220 // and variants
Publisher
ESTA Apparatebau GmbH & Co. KG Tel.: [phone]
Gotenstr. 2-6 Fax: [phone]
89250 Senden Email: [email protected]
Germany www.esta.com
Copyright notice (per DIN ISO 16016:2007-12)
Transfer or reproduction of this document, or the use or communication of its content, is forbidden
without explicit consent. Violators will be liable for damages. All rights to patent, utility or design
registration are reserved.

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Table of contents
Table of contents...................................................................................................................3
1General instructions........................................................................................................4
1.1 Target group.............................................................................................................4
1.2 Tips ..........................................................................................................................4
2Product identification......................................................................................................5
2.1 Technical Data .........................................................................................................5
2.2 Intended application.................................................................................................6
3Product description.........................................................................................................8
3.1 Product illustration VACUMAT 1000 / 2200 active carbon filter................................8
3.2 Functional description ..............................................................................................9
4Safety..............................................................................................................................10
4.1 Hazard categories..................................................................................................10
4.2 Symbol explanation................................................................................................10
4.3 General safety instructions.....................................................................................12
4.4 Preventing mechanical hazards .............................................................................12
4.5 Preventing electrical hazards .................................................................................13
4.6 Preventing dust hazards.........................................................................................15
5Delivery and commissioning........................................................................................16
5.1 Delivery and transport ............................................................................................16
5.2 Connection.............................................................................................................17
5.3 Function check.......................................................................................................19
5.4 Commissioning.......................................................................................................20
5.5 Suction line connection ..........................................................................................20
5.6 Troubleshooting during commissioning..................................................................21
6Operating instructions..................................................................................................22
6.1 Control panel..........................................................................................................22
6.2 Operate product .....................................................................................................22
7Maintenance & troubleshooting...................................................................................23
7.1 Maintenance instructions........................................................................................23
7.2 Inspection and maintenance intervals ....................................................................24
7.3 Detaching the filter mat outlet element...................................................................26
7.4 Detaching the filter mat active carbon filter ............................................................27
7.5 Replace active carbon filter....................................................................................28
7.6 Clean product.........................................................................................................30
7.7 Store product..........................................................................................................30
7.8 Eliminating faults....................................................................................................30
8Disposal .........................................................................................................................32
8.1 Dispose of product .................................................................................................32
9EC/EU Declaration of Conformity.................................................................................33
Notes.....................................................................................................................................34
Notes.....................................................................................................................................35

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1 General instructions
1.1 Target group
These instructions are intended for
Skilled warehousing and logistics personnel responsible for transport
Operators trained on the product who are familiar with the extraction
process,
service, cleaning and maintenance staff trained on the product.
Trained electrical specialists.
1.2 Tips
Before operation, all persons who are to use the product or perform maintenance
on it must be provided with information, instructions and training in using the
product and on the substances for which it is to be used, including the procedure
for safe disposal of the collected material. Responsibilities must be clearly
established for the following
Installation
Commissioning
Operation
Maintenance and repairs
Read the instructions carefully before working with the product.
The product may only be used by persons who have been instructed in its handling
and are explicitly authorised to use it.
Always keep the instructions at the place where the product is being used, so that
they can be seen by personnel at all times.
These instructions describe the product at the time of first delivery following
manufacture.
Keep the documents throughout the product'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.

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Further documents are available on top of these instructions. You can request any
documents required from ESTA.
Where applicable, instructions on optional equipment
2 Product identification
2.1 Technical Data
We reserve the right to make technical changes
Item no.
07100
07220
VACUMAT type
1000
2200
Drive power
[kW]
1.1
2.2
Connection voltage
[V]
400
Nominal frequency
[Hz]
50
Nominal current
[A]
2.4
4.5
Circuit breaker
[A]
16 (circuit breaker)
Protection class
IP 54
Max. vacuum
[Pa]
1,250
2,550
Max. volume flow
[m³/h]
1,010
2,250
Filter class
F9
average sound pressure level LpA*
[dBA]
62
71
Dimensions L x W x H
(incl. filter unit)
[mm]
1,050 x 800 x 1,330
Weight of active carbon filter
[kg]
30
Dimensions of active carbon filter
[kg]
25
Total weight (including filter unit)
[kg]
215
218
Production year
See model plate
* using the enveloping surface method DIN EN ISO 3744, measured at minimum volume flow; noise measurement margin
of error approx. 4 dBA
** Custom voltage on request

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2.2 Intended application
2.2.1 Ambient conditions
Ambient temperature
[°C]
540
Rel. humidity
[%]
30 - 70
min. spatial requirement around the
product
Operator's side (front)
Inlet
Outlet
Rear
Top
[mm]
1,000
1,000
1,000
500
1,000
2.2.2 Intended use
The product has been manufactured based on state-of-the-art technology and
according to recognized safety regulations and must be used as intended:
as central extraction system for environmental pollutants and noxious
odours,
for commercial use, such as in industrial enterprises and workshops,
for extraction in individual workplaces.
Only for dry cleaning.
Other applications are considered unintended use. ESTA is not liable for damages
due to unintended use!

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2.2.3 Improper use
The product has been manufactured according to the state of the art and
recognized 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 product during suction operation.
Do not set up or operate in dust/gas-explosive areas.
Do not use in painting operations.
Do not connect to processing machines that may produce active ignition
sparks or hot embers.
Do not suck up liquids.
Do not suck up aggressive gases.
Do not suck up any readily flammable or glowing particles.
Do not suck up dusts and particles.
2.2.4 Reasonably foreseeable misuse
Do not suck up hot embers, such as cigarette butts.
Do not cause complete closure of the suction openings.

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3 Product description
3.1 Product illustration VACUMAT 1000 / 2200 active carbon filter
Control panel
Cover
Outlet element
Fan unit
Filter mats
Active carbon
filter
Locking castor

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3.2 Functional description
The product is equipped with a three-phase motor which drives a radial fan. The
product is supplied with or disconnected from the requisite power via a main switch.
The fan is turned on and off via the control panel. The operating hourscounter serves
for orientation for filter change and maintenance intervals.
Due to the negative pressure produced by the fan, air is sucked in through the active
carbon filter unit. This separates the odours and pollutants located in the air which is
sucked in. The purified air is guided back into the room through the outlet openings
on the exhaust air grilles.

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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 categorized as
follows:
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 product
or parts of it.
CAUTION
Instruction about a hazard.
Failure to comply can lead to slight injury and to damage to the product.
4.2 Symbol explanation
Further information
Reference to ESTA customer service
Reference to legal regulations

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4.2.1 Symbols on the product
Before commissioning, read and observe the operating instructions and safety
instructions (per ISO 11684)
Do not take in glowing dust or other sources of ignition. Do not use in
conjunction with spark-generating machinery.
Warning of hand injuries (as per BGV A8 W27)
Type plate:

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4.3 General safety instructions
During extraction, the volume flow returned from the product 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 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 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 product must be disconnected from the power supply
immediately, turned off at the main switch and the plug pulled immediately.
If there is a fire, alert the fire department immediately, and contain the fire by
appropriate means. Therefore keep a suitable extinguishing agent near the
product before start-up and during operation.
4.4 Preventing mechanical hazards
WARNING
Crushing hazard due to loose or open covers during operation
Keep covers tightly closed during operation!
WARNING
Risk of falling due to improper handling of the lifting device.
Always pay attention to the local accident prevention regulations.
The lifting device protrudes from the product when at rest.
Do not stand on the lifting device.
All movable machine parts driven by electric motors must be covered by fixed,
securely fastened protective covers that can be removed only with tools.

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CAUTION
Injuries from spontaneous movement by running over and crushing
Wear personal protective equipment. (safety shoes)
Do not place the product on a sloping surface.
Always make sure that the castor’s lock is activated during placement.
Make sure that the surface can be driven on, is level and sufficiently load
bearing.
Watch out for pipe or hose connections and other valves, or disconnect if
required.
CAUTION
Risk of tipping over when moving the product with the filter unit lid open.
Keep the filter unit lid closed when moving.
CAUTION
Risk of spontaneous movement due to unsuitable floor
Make sure that the surface can be driven on, is level and sufficiently load
bearing.
4.5 Preventing electrical hazards
DANGER
Electric shock from high voltages
Follow the safety rules for working with electrical products!
Secure the product against reactivation with a padlock!
Render the product 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.
DANGER
Electric shock from high voltages when power cable is damaged
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!
Any work on the electrical grid and on voltage-conducting parts may only
be performed by an electrical specialist.
Use only original ESTA replacement parts.

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DANGER
High-voltage electric shock when working on the running product
Turn off at the main switch and secure with a padlock against reactivation!
Render the product 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.
DANGER
Residual hazard from loose or open covers
Keep covers closed during operation!
Any work on the electrical grid and on voltage-conducting parts may only
be performed by an electrical specialist.
All electrical parts must be covered by fixed, securely fastened protective covers
that can be removed only with tools. The product complies with Protection Class I
according to EN 60335.
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 unplug the mains connector.

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4.6 Preventing dust hazards
CAUTION
Damage due to dust release
Maintenance, cleaning, repair and emptying work must be done only by
expert personnel.
Wear personal protective gear.
- Respirator mask (particle filter class P3)
- Protective clothing
- Protective gloves
Set up locally filtered forced-air ventilation where the product is being
maintained, inspected or cleaned.
Operate the product 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
resulting minimum airflow volume.
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
resulting minimum airflow volume.
When replacing the active carbon filter, it is impossible to
preclude the inhalation of dust. That is why all servicing, cleaning
and maintenance procedures, including removal and emptying, is
only to be performed by specialist personal with personal
protective equipment.
The people assigned to cleaning work must be instructed on the
aspirated toxic materials. Harm to bystanders and the
environment must be prevented by all means. Clean the
maintenance area thoroughly once maintenance is complete.

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5 Delivery and commissioning
5.1 Delivery and transport
DANGER
Danger from falling product
Do not walk under heavy and suspended loads.
The lifting and transporting equipment must be designed for the weight of
the product.
WARNING
Crushing hazard if the product settles during transport
Secure the product during transport.
Wear safety shoes.
CAUTION
Risk of damaging the product due to improper transport.
Do not push the product over the floor if it does not have any rollers.
Use only suitable lifting and transport equipment (such as a forklift or lift
truck) when transporting the product to its set-up location.
Watch out for the centre of gravity –which is not in the centre –when
positioning.
Make sure the floor has adequate weight capacity and can be properly driven on
when transporting the product.
Upon delivery inspect the product for transportation damage. Damage determined
must be reported and documented immediately.
At delivery, the product is fastened to a pallet.
Remove the protective cover and floor securing devices.
Check the delivery is complete
Suspend the product using sling gear (e.g. a lifting belt, round sling) at the
positions provided, lift it from the pallet and place it down on the ground.
Lift the product from the pallet using a forklift at the positions provided and
place it down on the ground.
Note total weight and centre of gravity during all transport work.
Use the attached rollers for further transport to its installation location.

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ESTA customer service: [phone] - 0
5.2 Connection
Before establishing cable connections between the product and the mains, check
whether the operating voltage specified on the rating plate matches that of the
mains.
Place the product on an even surface as close as possible to the source of odour
or pollutant. Ensure the product is aligned horizontally when setting it up.
5.2.1 Control unit description
The control unit is equipped with the following elements.
1) MAIN SWITCH
For switching the product on and off.
This switch also serves as an EMERGENCY STOP switch and can be secured
with a lock against unintentional activation.
2) OPERATING UNIT
Extraction is started and stopped on the control panel and serves to control rotation
direction.
3) PHASE SEQUENCE CONTROL
The control lights of the phase sequence monitor light up when the fan rotor of the
motor turns in the wrong direction.
4) OPERATING HOURS COUNTER
The operating hours counter serves for orientation of the intervals for filter change
and filter maintenance.
1
4
2
3

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5.2.2 Electrical connection
DANGER
Electric shock from high voltages
Follow the safety rules for working with electrical products!
Secure the main switch against reactivation with a padlock when working
on the product.
Any work on the electrical grid and on voltage-conducting parts may only
be performed by an electrical specialist.
A CEE wall socket with a slow-blow fuse must be in place to supply the product
with power.
Connection to the building's power supply is made at the installation location.
VACUMAT
1000 / 2200
Connection plug
[Amp.]
CEE 16 Amp.
Mains (standard)
Three-phase
current
400V/50Hz
3N ~
Fuse
[Amp.]
C16A (circuit
breaker)
* Custom voltage on request; observe the specifications on the rating plate.
5.2.3 Activation operations for motors:
Motors with high output without frequency converters should be not be switched
on and off within a short period of time too frequently. Otherwise, electrical
components could be overloaded. Please observe the specifications for the
number of activation operations:
Motor output
Activation operations per hour
1 –4 KW
Up to 8 starts
4 –7.5 KW
Up to 6 starts
7.5 –15 KW
Up to 4 starts
15 –30 KW
Up to 3 starts
From 30 KW
Electronically controlled overrun time

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5.3 Function check
Before the product is first used, a function check must be performed.
Turn the main switch to position "I" for a product function check.
5.3.1 Rotation direction monitoring
When the direction of rotation is incorrect, the product becomes impermissibly hot,
the volume increases, the airflow volume falls, and the product’s suction performance
suffers. Damage to the product cannot be ruled out.
After first switching on the product, you should check that the fan rotor’s direction of
rotation is correct.
1. Switch on the product at the main switch.
2. Rotation direction monitor light lights up.
3. Turn the product off at the main switch.
4. Pull the power plug.
DANGER
Electric shock from high voltages
Any work on the electrical grid and on voltage-conducting parts may only be
performed by an electrical specialist.
5. Insert the power plug.
6. Turn the product on at the main switch.
7. The product is ready for operation.
8. Turn the product off at the main switch.

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5.4 Commissioning
Use original ESTA accessories.
Once a functional inspection has been completed, the connection is made to the
processing apparatus that is to be extracted.
1. Disconnect the compressed air supply.
2. Pull the power plug.
3. Place the product on an even surface as close as possible to the work
station.
4. Insert the power plug.
5. Connect the compressed air.
5.5 Suction line connection
Connect the processing machine to be vacuumed to the filter unit's intake port
through a pipe or hose line.
For a suction line, use
an appropriate suction hose that meets the national requirements for
this application.
an appropriate pipe (wrap fold) that meets the national requirements
for this application.
approved adapters for short diameter on the connection piece