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Troubleshooting
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Summary of Contents for Esta OILMAC 800
- Page 1 The World of Extraction OILMAC Oil Mist Extractor...
- 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 OILMAC 800 OILMAC 1600 with backup filter stage H13 with backup filter stage combination mesh OILMAC 800 (order no.: 56201) OILMAC 800 (order no.: 56211) OILMAC 1600 (order no.: 56202) OILMAC 1600 (order no.: 56212) Do not use this device unless you have read the operating instructions and understood them.
- Page 4 Type of device: OILMAC oil mist separator Article no.: 56.201 // 56.202 // 56.211 // 56.212 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...
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Page 5: Table Of Contents
Improper use ......................8 2.2.4 Reasonably foreseeable misuse ................8 3. Product Description ......................9 Picture of the device ....................9 3.1.1 OILMAC 800 ......................9 3.1.2 OILMAC 1600 ....................... 9 Separation and filter elements ................10 3.2.1 Pre-filter ......................10 3.2.2... - Page 6 10.1 Declaration of incorporation for incomplete machines pursuant to EC guideline 2006/42/EC, Appendix II, Part 1 B ..............44 10.1.1 OILMAC 800 (without ESTA motor circuit breaker) ..........44 10.1.2 OILMAC 1600 (without ESTA motor circuit breaker) .......... 46 10.2 EU/EC Declaration of conformity for machines pursuant to EU/EC guideline 2006/42/EC, Appendix II, Part 1 A ..............
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Page 7: General Instructions
1. General instructions 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 device and on the substances for which it is to be used, including the procedure for safe disposal of the collected material. -
Page 8: Product Identification
2. Product identification 2.1 Technical data 2.1.1 With backup filter stage H13 We reserve the right to make technical OILMAC changes. 1600 Item no. 56201 56202 Max. volume flow [m³/h] 1,800 Drive power [kW] 0.55 Connection voltage Nominal frequency [Hz] Nominal current Circuit breaker Protection class... -
Page 9: With Backup Filter Stage Combination Mesh
2.1.2 With backup filter stage combination mesh We reserve the right to make technical OILMAC changes. 1600 Item no. 56211 56212 Max. volume flow [m³/h] 1,800 Drive power [kW] 0.55 Connection voltage Nominal frequency [Hz] Nominal current Circuit breaker Protection class IP 54 IP 54 ø... -
Page 10: Intended Use
Approved for air recirculation operation with backup filter stage H13. Approved for air extraction operation with backup filter stage combination mesh. Other applications are considered unintended use. ESTA is not liable for damages due to unintended use! The manufacturer sets up the device according to the operator’s information. -
Page 11: Product Description
3. Product Description Picture of the device 3.1.1 OILMAC 800 Filter unit Inlet element Intake port Fan unit with motor 3.1.2 OILMAC 1600 Inlet element Filter unit Fan unit with Intake port motor 56201-52-08 OILMAC... -
Page 12: Separation And Filter Elements
Separation and filter elements 3.2.1 Pre-filter The separation and filter elements are designed so that the air is filtered mechanically through several stages of filtration. The pre-separator consists of the following filter elements: 1. Pre-filter metal mesh 2. Pre-filter fibre mat 3. -
Page 13: Backup Filter Stage
3.2.2 Backup filter stage The separation and filter elements are designed so that the air is filtered mechanically through several stages of filtration. Depending on the design, the backup filter is designed as: 1. Backup filter stage H13 2. Backup filter combination mesh 56201-52-08 OILMAC... -
Page 14: Functional Description
Functional description The device is equipped with a three-phase motor which drives a radial fan. Due to the negative pressure created by the fan, air containing oil and emulsion is drawn from the processing machine through the suction hose connected to the device's intake port. -
Page 15: Symbol Explanation
Symbol explanation Further information Reference to ESTA customer service Reference to legal regulations 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. -
Page 16: Preventing Mechanical Hazards
4.4. Preventing mechanical hazards DANGER Risk of injury posed by the drawing-in or catching of hair or loose items (e.g. chains, hair, ties, etc.). Observe the safety regulations for work on devices with rotating parts! Before working on the device, turn it off and secure it against unintentional reactivation. -
Page 17: Preventing Material And Substance Hazards
Preventing material and substance hazards CAUTION Damage from improper handling of separated substances Maintenance, cleaning, repair and emptying work must be done only by expert personnel. Observe the instructions of the cooling lubricant manufacturer about handling these substances. ... -
Page 18: Delivery And Commissioning
Please inspect the device for transportation damage when it arrives. Damage determined must be reported and documented immediately. ESTA customer service: +49 (0) 7307 804 - 0 Make sure the floor has adequate weight capacity and can be properly driven on when transporting the device. -
Page 19: Connection
Connection Before establishing cable connections between the device and the mains, check whether the operating voltage specified on the rating plate matches that of the mains. The device must always be set up horizontally on a rigid, vibration-insulated surface. Bolt the device tightly together with the processing machine. In so doing, watch out for the minimum required clearances from ceilings and walls. -
Page 20: Electrical Connection
5.2.1 Electrical connection DANGER Electric shock from high voltages Follow the safety rules for working with electrical devices! Only operate the device with a suitable, lockable motor circuit breaker! When working on the device, disconnect it from the voltage supply! ... -
Page 21: Suction Line Connection
5.2.2 Suction line connection You should generally attach baffle plate to the extraction opening of your processing machine. This should keep out cooling lubricant droplets and chips. Wall clearance: Approx. 100 mm Extraction opening cover: Min. 100 mm (all sides) A suction pipe must be laid on site for connecting the device to the processing machine. -
Page 22: Siphon Connection
5.2.3 Siphon connection Connection thread ["] Spout diameter [mm] Underneath the device there are outlet openings on the inlet element and on the filter unit for connecting a siphon pipe. Separated cooling lubricant is drained through these. To make sure this cooling lubricant drains properly and to prevent the unwanted intake of false air, a filled siphon connection must be installed at this port. -
Page 23: Function Check
Function check Before the device is first used, a function check must be performed. Switch the device on for a function check. 5.3.1 Rotation direction monitoring When the direction of rotation is incorrect, the device becomes impermissibly hot, the airflow volume falls, and the device’s performance suffers. Damage to the device cannot be ruled out. -
Page 24: Commissioning
Commissioning Use original ESTA accessories. Once a functional inspection has been completed, the connection is made to the processing machine that is to be extracted. Install the suction pipe. Install the siphon connections. Troubleshooting during commissioning Fault Possible cause... -
Page 25: Operating Instructions
6. Operating instructions Operating the device After connecting the suction hose to the processing machine: Switch on the oil mist separator Start the processing operation. During operation, do not change the device’s location. When finishing the processing operation: ... - Page 26 CAUTION Damage from improper filter installation Set up locally filtered forced-air ventilation where the device is being maintained, inspected or cleaned. Operate the device only with the complete filtration system. Always pay attention to the arrangement and installation location of the filters. ...
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Page 27: Inspection And Maintenance Intervals
Check – and where appropriate, clean or replace – the separation and filter elements Check siphon connections for blockages, and clean these if necessary The main annual inspection includes: The last test by ESTA is documented on the device. In collaboration with the ESTA maintenance service Flow volume measurement ... -
Page 28: Spare And Wear Parts
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 OILMAC series Replacement parts 1600... -
Page 29: Cleaning And Replacing The Separation And Filter Elements
Cleaning and replacing the separation and filter elements After an extended period of operation, the filters clog up by slowly due to the ingress of extremely fine dust (wear debris), chip deposits, resinous oil, and fatty residues in the pores. The filters must be cleaned or replaced. This work may only be performed by trained personnel! The pre-separator consists of the following filter elements: 1. -
Page 30: Cleaning And Replacement Intervals
7.3.1 Cleaning and replacement intervals Replaceme Cleaning Separation and filter element At least 1. Pre-filter aluminium wire mesh As required monthly At least 2. Pre-filter filter pad monthly At least 3. Main separator labyrinth filter As required monthly 4. Pre-filter fibreglass mat As required 5a. -
Page 31: Pre-Filter Aluminium Wire Mesh
Replace or clean the individual filter elements as required. Arrange all filter elements in the correct order, quantity, and installation location in the pre-separator. → It is imperative that you pay attention to the direction of flow through the labyrinth filter. -
Page 32: Pre-Filter Filter Pads
7.3.4 Pre-filter filter pads Wherever possible, work should be carried out during non-working hours. Take the pre-separator out of the device as described and place it in a suitable container. The individual filter elements can be taken out of the frame by tipping the pre-separator. ... -
Page 33: Pre-Filter Labyrinth Filter
7.3.6 Pre-filter labyrinth filter Wherever possible, work should be carried out during non-working hours. Take the pre-separator out of the device as described and place it in a suitable container. The individual filter elements can be taken out of the frame by tipping the pre-separator. ... -
Page 34: Backup Filter Stage Filter Element
7.4. Backup filter stage filter element 7.4.1 Backup filter stage H13 Wherever possible, work should be carried out during non-working hours. Switch the device off and secure it against unintentional reactivation. Wait until the fan has come to a stop. ... -
Page 35: Backup Filter Stage Combination Mesh
7.4.2 Backup filter stage combination mesh Wherever possible, work should be carried out during non-working hours. Switch the device off and secure it against unintentional reactivation. Wait until the fan has come to a stop. Release the quick releases on the fan unit. ... -
Page 36: Siphon Connection Maintenance
Siphon connection maintenance The siphon connections can get blocked up, especially with sludge-like substances. These must therefore be cleaned regularly. Switch the device off and secure it against unintentional reactivation. Wait until the fan has come to a stop. ... -
Page 37: Cleaning Filter And Separation Elements That Can Be Cleaned
Cleaning filter and separation elements that can be cleaned Clean filter and separation elements at the intervals specified. To do this: Remove deposits of oil and emulsion residue, resinous oil, and fine dusts With a damp disposable cloth. With warm water. With degreasing cleaning agents. -
Page 38: Troubleshooting
Troubleshooting DANGER High-voltage electric shock when working on the open switch box Follow the safety rules for working with electrical devices! Secure the device against reactivation with a padlock! Isolate device! Any work on the electrical grid and on live components parts may only be performed by an electrician. - Page 39 Smoke development or Imbalance in the fan. Turn the device off load running noises of the immediately and have ESTA customer service inspect the fan. Rotor is scraping on the Switch off the device inlet nozzle or the immediately and: housing.
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Page 40: Disposal
Warm water. Degreasing cleaning agents. Everything must be packaged and disposed of in accordance with local regulations for the removal of such waste. Due to contamination of the device with toxic substances, ESTA cannot take the device back. OILMAC 56201-52-08... -
Page 41: Optional Equipment
(packaged with the device). PIN 3 is reserved for the neutral conductor. This is only required when using special ESTA accessories. The potential equalisation is connected to the PIN with the marking for protective ground. (Please observe the circuit documentation enclosed!) As soon as the main switch is set to “ON”, the contacts to the device’s black socket... -
Page 42: Air Vents
Air vents The device can be fitted with an optional discharge air port or upgraded. As a result, it is possible to connect a customer-side discharge air line (hose or pipe) to channel the discharge air out into the open, for example. The outflow must remain free to keep the flow rate constant. -
Page 43: Connecting The Discharge Airline To Discharge Air Ports
9.2.1 Connecting the discharge airline to discharge air ports Install the discharge airline as follows: Connect the discharge air port of the oil mist separator with a flexible pipe which is easy to disassemble Ensure this is without kinks as much as possible ... -
Page 44: Mobile Design
Mobile design The device can come in an optional mobile design. This version of the device comes with a dolly. The dolly is equipped with casters and brake rollers. This allows the device to be moved easily to a different location. This is an advantage when no suitable lifting device (such as a forklift or indoor crane) is available. -
Page 45: Saturation Display
Saturation display The device can be fitted with an optional saturation display or upgraded. This enables read-off of the level of soiling in the filter. The end pressure for changing the filter, or for filter cleaning if required, is set at the factory so that the maximum filter differential pressure is not exceeded. -
Page 46: Declarationen
10. Declarationen 10.1 Declaration of incorporation for incomplete machines pursuant to EC guideline 2006/42/EC, Appendix II, Part 1 B 10.1.1 OILMAC 800 (without ESTA motor circuit breaker) ESTA Apparatebau GmbH & Co. KG Name of manufacturer: Gotenstraße 2 - 6... - Page 47 National norms and technical specifications used: Filtering separators VDI 3677 Safety and health protection requirements according to 2006/42/EC Appendix I that are applied and observed: 1.1.1; 1.1.2; 1.1.3; 1.1.5; 1.3; 1.3.1; 1.3.2; 1.3.3; 1.3.4;1.3.7; 1.3.9; 1.4; 1.4.1; 1.4.2; 1.4.2.1; 1.4.2.2; 1.5; 1.5.2; 1.5.4; 1.5.5; 1.5.6; 1.5.7; 1.5.8; 1.5.9; 1.5.10; 1.5.13; 1.6; 1.6.1; 1.6.2; 1.6.4; 1.6.5;...
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Page 48: Oilmac 1600 (Without Esta Motor Circuit Breaker)
10.1.2 OILMAC 1600 (without ESTA motor circuit breaker) Name of manufacturer: ESTA Apparatebau GmbH & Co. KG Gotenstraße 2 - 6 Address of manufacturer: 89250 Senden Name of the authorised document representative: ESTA Apparatebau GmbH & Co. KG Gotenstraße 2 - 6... - Page 49 National norms and technical specifications used: VDI 3677 Filtering separators Safety and health protection requirements according to 2006/42/EC Appendix I that are applied and observed: 1.1.1; 1.1.2; 1.1.3; 1.1.5; 1.3; 1.3.1; 1.3.2; 1.3.3; 1.3.4;1.3.7; 1.3.9; 1.4; 1.4.1; 1.4.2; 1.4.2.1; 1.4.2.2; 1.5;...
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Page 50: Eu/Ec Declaration Of Conformity For Machines Pursuant To Eu/Ec Guideline 2006/42/Ec, Appendix Ii, Part 1 A
10.2 EU/EC Declaration of conformity for machines pursuant to EU/EC guideline 2006/42/EC, Appendix II, Part 1 A 10.2.1 OILMAC 800 (with ESTA motor circuit breaker) ESTA Apparatebau GmbH & Co. KG Name of manufacturer: Address of manufacturer: Gotenstraße 2 - 6... -
Page 51: Oilmac 1600 (With Esta Motor Circuit Breaker)
10.2.2 OILMAC 1600 (with ESTA motor circuit breaker) Name of manufacturer: ESTA Apparatebau GmbH & Co. KG Gotenstraße 2 - 6 Address of manufacturer: 89250 Senden Name of the authorised document representative: ESTA Apparatebau GmbH & Co. KG Gotenstraße 2 - 6... -
Page 52: 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 Email: info@esta.com www.esta.com OILMAC 56201-52-08... -
Page 53: 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 Email: info@esta.com www.esta.com 56201-52-08 OILMAC... - Page 54 ESTA Apparatebau GmbH & Co. KG Gotenstraße 2 - 6 89250 Senden / Ay Tel.: +49 (0) 7307 804 - 0 Fax: +49 (0) 7307 804 - 500 Email: info@esta.com www.esta.com...
- Page 55 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 56 • 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...
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