Esta DUSTOMAT 4 ATEX Operating Instructions Manual
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Esta DUSTOMAT 4 ATEX Operating Instructions Manual

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The World of Extraction
DUSTOMAT 4 – ATEX
Mobile Dust Extractors

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Summary of Contents for Esta DUSTOMAT 4 ATEX

  • Page 1 The World of Extraction DUSTOMAT 4 – ATEX Mobile Dust Extractors...
  • Page 2 The World of Extraction Welcome to the sphere of suction technology 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.
  • Page 3 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...
  • Page 4 07.05.2018 Type of device: DUSTOMAT 4 ATEX Article no.: 09.732 // 09.762 and versions Publisher ESTA Apparatebau GmbH & Co. KG Tel.: +49 (0) 73 07 80 4 -0 Gotenstr. 2-6 Fax: +49 (0) 73 07 80 4 -500 89250 Senden Email: info@esta.com...

  • Page 5: Table Of Contents

    Product identification ......................... 7 Technical Data ......................7 Intended application ....................8 Product Description ........................10 Illustration of the DUSTOMAT 4 ATEX device ............10 Functional description .................... 11 Minimum volume flow monitoring ................11 Safety ............................12 Hazard categories ....................12 Symbol explanation ....................
  • Page 6 ContentsContents 11.2 General notes for the user ..................52 11.3 Special notes for the user ..................53 Notes..............................54 Notes..............................55 DUSTOMAT 4 ATEX 09732-52-01...

  • Page 7: General Instructions

    Maintenance Technical training with knowledge and - Safety shoes Electrical spe- experience for iden- - Hearing protection cialist tifying and prevent- - Work gloves ing hazards posed by electricity 09732-52-01 DUSTOMAT 4 ATEX...

  • Page 8: Tips

     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. DUSTOMAT 4 ATEX 09732-52-01...

  • Page 9: Product Identification

    1.000 Outlet Rear 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 09732-52-01 DUSTOMAT 4 ATEX...

  • Page 10: Intended Application

     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.
  • Page 11 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 09732-52-01 DUSTOMAT 4 ATEX...

  • Page 12: Product Description

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

  • Page 13: Functional Description

    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. 09732-52-01 DUSTOMAT 4 ATEX...

  • Page 14: Safety

    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 DUSTOMAT 4 ATEX 09732-52-01...
  • Page 15 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. 09732-52-01 DUSTOMAT 4 ATEX...

  • Page 16: General Safety Instructions

    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. DUSTOMAT 4 ATEX 09732-52-01...

  • Page 17: Preventing Mechanical Hazards

    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. 09732-52-01 DUSTOMAT 4 ATEX...

  • Page 18: Atex Hazard Prevention

    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.

  • Page 19: Preventing Electrical Hazards

    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. 09732-52-01 DUSTOMAT 4 ATEX...

  • Page 20: Preventing Dust Hazards

    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. DUSTOMAT 4 ATEX 09732-52-01...

  • Page 21: Preventing Noise Hazards

    To do this: Turn the device off at the main switch Cut off the power supply by pulling the electrical plug The manometer attached to the compressed air tank is used for monitoring the pressure in the tank. 09732-52-01 DUSTOMAT 4 ATEX...

  • Page 22: Delivery And Commissioning

    5. Pay attention to the weight of the device and its centre of gravi- ty during all transport work. 6. Use the attached rollers for further transport to its installation location. DUSTOMAT 4 ATEX 09732-52-01...

  • Page 23: Connection

    Connection to the building's power supply is made at the installation location. DUSTOMAT 4-10 4-24 Connection plug [Amp.] CEAG-CEE 16 Three-phase current Mains (standard) 400V/50Hz 3N ~ Fuse [Amp.] C16A (circuit breaker) * Custom voltage on request; observe the specifications on the rating plate. 09732-52-01 DUSTOMAT 4 ATEX...
  • Page 24 2) CONTROL PANEL Suction is started/stopped on the control panel. In addition, all status and error messages are shown in plain text on the display. Furthermore, device settings can be adjusted. DUSTOMAT 4 ATEX 09732-52-01...
  • Page 25 4-10 4-24 Compressed air quality (ISO 8573- Class 3.2.2 1:2010-04) Pressure [bar] 4 - 6 Connection-ø [''] 1/4 (ø9mm) Compressed air consumption * [l/pulse] * at 4 bar with a valve opening time of 0.12 sec. 09732-52-01 DUSTOMAT 4 ATEX...

  • Page 26: Function Check

    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 EN 60079-  The operator is to ensure that conductible extraction systems (e.g. extrac- tion hood and pipe line) and conductible processing machine (e.g.
  • Page 27 1. Turn the phase inverter in the CEE plug. 2. Insert the power plug. 3. Switch on the device at the main switch. DUSTOMAT The device is ready for operation. Ready for operation 4. Turn the device off at the main switch. 09732-52-01 DUSTOMAT 4 ATEX...

  • Page 28: Commissioning

    Delivery and commissioning 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 product from the compressed air supply. 2. Switch the product on via the connected main system.
  • Page 29 3. Insert a new, empty disposal carton into the bracket of the collection drawer. 4. Push the collection drawer fully back into the product. 5. Push the lifting device lever down so that the collection drawer is closed upwards tightly. 09732-52-01 DUSTOMAT 4 ATEX...

  • Page 30: Troubleshooting During Commissioning

    The desired air quantity is in the connector. not reached. The supply cable's prelimi- Motor was switched on/off Please consult the "Activa- nary fuse has tripped. too often within a short peri- tion operations for motors" od of time. table. DUSTOMAT 4 ATEX 09732-52-01...

  • Page 31: Operating Instructions

    Operating instructions Operating instructions 6.1 Control panel of the ESTA control system (standard) Switch on the device at the main switch. The suction in manual mode is then switched on and off by pressing the "ON/OFF" button. ON/OFF switch Main switch Display for show messages, instructions and operating states.

  • Page 32: Operating The Device

    Betriebsbereit. Operating instructions 6.1.1 Operating via the control panel of the ESTA control system ESTA dust extractor Once the device has been switched on at the main switch it is ready for Ready for operation operation. In this process the suction is not activated.

  • Page 33: Jet Pulse Cleaning

    (Jet-pulse cleaning). For this, compressed air is needed. Always connect oil and water-free compressed air to ensure operational safety and product availabil- ity. Jet-pulse cleaning provides the following functions:  Automatic cleaning during suction operation  Automatic post-cleaning  Manual cleaning 09732-52-01 DUSTOMAT 4 ATEX...
  • Page 34  Press the "cleaning-test" button on the switch cabinet. Pulse-like compressed air blasts are blown into the filter cartridges one af- ter the other.  Wait at least 5 minutes until the cleaning cycle has been completed before opening the extraction system. DUSTOMAT 4 ATEX 09732-52-01...

  • Page 35: Maintenance & Troubleshooting

    Protective clothing Protective gloves  Set up locally filtered forced-air ventilation where the device is being main- tained, inspected or cleaned.  Seal the intake port with a sealing plug so it is dust-tight when transporting. 09732-52-01 DUSTOMAT 4 ATEX...
  • Page 36 When there is a malfunction, switch the device off immediately and contact the responsible maintenance service! ESTA maintenance service: +49 (0) 7307 804 - 0 ESTA replacement part service: +49 (0) 7307 804 - 0 DUSTOMAT 4 ATEX 09732-52-01...

  • Page 37: Inspection And Maintenance Intervals

    Gas pressure absorbers on the Function check filter unit lid Replace Volume flow Measurement Negative pressure Measurement Power consumption Measurement Visual inspection Filter Replace Whole device tightness Function check Visual inspection Compressed air tank Discharge con- densation 09732-52-01 DUSTOMAT 4 ATEX...
  • Page 38 7.2.1 Spare and wear parts Use original ESTA replacement and wear parts! With the device's model information and serial number, request the replacement parts you need from ESTA replacement part service: +49 (0) 7307 804 - 0 Unit 4-10 4-24...

  • Page 39: Detaching The Filter Mat Outlet Element

    Attach potential equalisation to the cover. 13. Insert the fastening screws of the cover and tighten them. 14. Re-attach the compressed air supply. 15. Re-insert the power plug. The device is now ready to operate again. 09732-52-01 DUSTOMAT 4 ATEX...

  • Page 40: Clean The Air Guide Plate

    Depending on the type of application, a week- ly check of the external and internal sides of the air guide plate is nec- essary. If adhesions are detected in this process, these must be re- moved. DUSTOMAT 4 ATEX 09732-52-01...
  • Page 41 13. Insert the fastening nuts around the air guide plate and screw these in tightly. 14. Push the pipe or hose line onto the intake connection piece and fix this firmly. 15. Re-attach the compressed air supply. => The product is now ready to operate again. . 09732-52-01 DUSTOMAT 4 ATEX...
  • Page 42 10. Push the collection drawer fully back into the device. 11. Push the lifting device lever down so that the drawer is closed upwards tightly. 12. Re-attach the compressed air supply. 13. Re-insert the power plug. => The device is now ready to operate again. DUSTOMAT 4 ATEX 09732-52-01...

  • Page 43: Replacing The Control Filter

    If possible, filter replacement must be done when there is no work going on. This process requires 2 people with personal protective gear. Also pay attention here to the supplementary maintenance instructions! 09732-52-01 DUSTOMAT 4 ATEX...
  • Page 44 9. Fasten the end of the bag securely with a cable tie. 10. Remove remaining filter cartridges as described. 11. Clean the rim around the opening for inserting the filter cartridge. Avoid raising dust DUSTOMAT 4 ATEX 09732-52-01...

  • Page 45: Policing Filter As A Secondary Filter Cassette (Dust Class H)

    25. Release the clamping nut on the filter cassette's hold-down clamp. 26. Turn the hold-down clamps to the side. 27. Take out the entire filter cassette from the bracket on the holding strap. 09732-52-01 DUSTOMAT 4 ATEX...
  • Page 46 35. Take the device cover and place this back on the device. 36. Insert the fastening nuts around the clamping profile and screw these in tightly. 37. Re-attach the compressed air supply. 38. Re-insert the power plug. 39. The device is now ready to operate again. DUSTOMAT 4 ATEX 09732-52-01...

  • Page 47: Eliminate Faults

    Damage from dust leaks and dust trails at air outlet openings.  Turn the device off at the main switch immediately. CAUTION Danger from the fan producing smoke and loud running noises  Turn the device off at the main switch immediately. 09732-52-01 DUSTOMAT 4 ATEX...
  • Page 48 "Control filter pipeline. full / operation Cleaning point set up too high. Contact ESTA customer ser- prohibited" vices to adjust the cleaning point. Motor protection trips. Motor was switched on/off too Please consult the "Activa-...

  • Page 49: Setting The Minimum Airflow Volume Monitoring

    With dusts that require a higher air velocity, this is to be adjusted where neces- sary. Regularly check the pipeline for dust deposits. Conduct a pipeline inspection on a weekly basis after putting into operation, so that you are able to define plant inspection and cleaning intervals. 09732-52-01 DUSTOMAT 4 ATEX...

  • Page 50: Clean The Device

    2. Empty the collection drawer and dispose of the collected material accord- ing to local regulations. 3. Clean the device inside and out. With a damp disposable cloth. With an industrial vacuum cleaner. Do not clean with a water jet! DUSTOMAT 4 ATEX 09732-52-01...

  • Page 51: Disposal

    4. Package the device and the detachable parts as specified by local regula- tions. 5. Dispose of everything according to local regulations. Due to contamination of the device with toxic dusts, ESTA cannot take the device or individual parts of it back. 09732-52-01...

  • Page 52: Optional Equipment

    Spark pre separator Optionally, a pre-separate isolated sparks carried along in the exhaust airflow and to minimise the risk of fire due to sparks and glowing particles. To this there’s ad- dition documentation DUSTOMAT 4 ATEX 09732-52-01...

  • Page 53: Ec-/Eu-Declaration Of Conformity

    EC-/EU-Declaration of Conformity 10 EC-/EU-Declaration of Conformity Name of manufacturer: ESTA Apparatebau GmbH & Co. KG Address of the manufacturer: Gotenstraße 2 - 6 89250 Senden Responsible for documentation: ESTA Apparatebau GmbH & Co. KG Gotenstraße 2 - 6 89250 Senden...

  • Page 54: Special Conditions For The User

    Ionising radiation Ultrasound Adiabatic compression and shock waves Exothermic reactions, auto-ignition of dust The suction of ignition sparks and hotspots The danger of ignition / the development of flammable gases or steams with chloride, fluoride, fluorine DUSTOMAT 4 ATEX 09732-52-01...

  • Page 55: Special Notes For The User

    Clean the device thoroughly and completely on the clean gas side (behind the filters) to prevent zone-crossing. Conduct a function of the control system check regularly, every 2,000 operating hours, to ensure the quality and functionality of the control system. 09732-52-01 DUSTOMAT 4 ATEX...

  • Page 56: Notes

    Notes Notes ESTA Apparatebau GmbH & Co. KG Gotenstraße 2 - 6 89250 Senden / Ay Tel.: +49 (0) 7307 804 - 0 Fax: +49 (0) 7307 804 - 500 e-mail: info@esta.com www.esta.com DUSTOMAT 4 ATEX 09732-52-01...

  • Page 57: Notes

    Notes Notes ESTA Apparatebau GmbH & Co. KG Gotenstraße 2 - 6 89250 Senden / Ay Tel.: +49 (0) 7307 804 - 0 Fax: +49 (0) 7307 804 - 500 e-mail: info@esta.com www.esta.com 09732-52-01 DUSTOMAT 4 ATEX...
  • Page 58 ESTA Apparatebau GmbH & Co. KG Gotenstraße 2 - 6 89250 Senden / Ay Tel.: +49 (0) 7307 804 - 0 Fax: +49 (0) 7307 804 - 500 e-mail: info@esta.com www.esta.com...
  • Page 59 ESTA-FAX: + 49 (0) 73 07 - 80 45 00 I want to order the following items: Amount Order-No. Item description My address: Customer-No.: Company: Address: Contact person: Phone: Fax: E-mail: Signature: www.esta.com...
  • Page 60 • Oil Mist Separators • Extraction Fans • Extraction Arms • Central Extraction Systems • Pipe Systems ESTA Apparatebau GmbH & Co. KG Gotenstrasse 2 – 6 D-89250 Senden, Germany Phone: +49 (0) 73 07 - 8 04 - 0 Fax: +49 (0) 73 07 - 8 04 - 500 E-Mail: info@esta.com...

This manual is also suitable for:

Dustomat 4-10 atexDustomat 4-24 atex0973209762

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