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Esta WELDEX FT Operating Instructions Manual

Stationary welding fume filtring systems
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The World of Extraction
WELDEX FT
Stationary
Welding Fume Filtring Systems

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Summary of Contents for Esta WELDEX FT

  • Page 1 The World of Extraction WELDEX FT Stationary Welding Fume Filtring Systems...
  • 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 manual WELDEX FT WELDEX FT-150 (Order No.: 667.150) Manual drawer WELDEX FT-150 (Order No.: 667.151) Pneumatic drawer WELDEX FT-230 (Order No.: 667.230) Manual drawer Do not use this unless you have read the user manual and understand it. Translation of the original instructions...
  • Page 4 Edition notice Original operating manual Document No.: 667150-08-08 Publishing date: 05.02.2015 Type of device: Modular welding fume filter system WELDEX FT Item No.: 667.150 // 667.151 / 667.230 and variations Publisher ESTA Apparatebau GmbH & Co. KG Tel.: +49 (0) 73 07 80 4 – 0 Gotenstraße 2-6...

  • Page 5: Table Of Contents

    15.1 Start-up with potential-free contact ..................27  15.2 Control filter ........................... 28  15.3 Alternative filter cartridges ....................28  15.4 Alternative control (ESTA control unit) .................. 28  15.5 Alternative control (Siemens-control) ..................42  15.6 Check valve at the suction opening ..................51 ...

  • Page 6: General Safety Notes

    The system is intended only for dry cleaning and must not be used or stored outdoors or under wet conditions. Only original ESTA replacement parts must be used; use of other products will void the warranty. During exhaust, the volume flow returned from the system into the room must be no more than 50% of incoming air.
  • Page 7 ATTENTION! Opening the upper door is permissible only if an appropriate waiting time has ensured that the impeller wheel inside is standing still — RISK OF INJURY! 667150-52-08 WELDEX FT...

  • Page 8: Preventing Mechanical Hazards

    If a covering that can only be unfastened with a tool is removed, a hazard is posed by electric current. The electrical connection and repair work must be done by a trained or appropriately qualified person (an electrical expert). WELDEX FT 667150-52-08...

  • Page 9: Preventing Dust Hazards

    Interrupt the pressure supply and empty the compressed air tank. This is done by performing a "manual cleaning" or by discharging the compressed air at the discharge valve of the compressed air tank. 667150-52-08 WELDEX FT...

  • Page 10: Preventing Hazards Tripping, Falling

    Other applications are considered unintended use. ESTA is not liable for damages due to unintended use! The manufacturer sets up the welding fume filter system according to the operator’s information.

  • Page 11: Technical Data And Description

    324 x 1,142 Dimensions Length 1,380 [mm] Width 2,055 Height 3,700 Max. air humidity 5  40 Environmental conditions [°C] Sound pressure level LpA [dBA] (per DIN EN ISO 3744) Weight [kg] approx. 1,400 Production year See model plate. 667150-52-08 WELDEX FT...

  • Page 12: Functional Description

    The optional dust bag is closed before removal, and removed by hand or with a lifting device, depending on weight. The coarse dirt bag can simply be removed from the cart and emptied. Disposal must be done in compliance with local regulations. WELDEX FT 667150-52-08...

  • Page 13: Delivery And Start-Up

    Upon delivery, please inspect the system for transportation damage. Damage determined must be reported and documented immediately. ESTA customer service: +49 (0) 7307 804 - 0 When transporting the system, make sure the ground can support it and be driven over.
  • Page 14 Make sure that the welding fume filter system is turned on first, and then the welding machine. When switching off, follow the same procedure in reverse. This can be ensured by using optional potential-free contact equipment. During operation, the welding fume filter system’s location should not be changed. WELDEX FT 667150-52-08...

  • Page 15: General Information For The Control

    Work on the controls may only be carried out by an electrical specialist or by a person trained for the purpose. Keep the work area around the system clear during the precoating process! This work should be done only by a professional! Keep all covers and inspection openings closed! 667150-52-08 WELDEX FT...
  • Page 16 2. Start the suction operation from the green button and let the powder to be carefully sucked over the fire extinguishing hole.  The pre-coating process is completed. WELDEX FT 667150-52-08...

  • Page 17: Switch-On Operations For Motors

    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 30 KW or more Electronically controlled follow-up time 667150-52-08 WELDEX FT...

  • Page 18: Troubleshooting At Start-Up

    The fuse on the supply The motor has been Please comply with the line triggers. turned on/off at short “Switch-on operations for intervals too often. motors” chart. WELDEX FT 667150-52-08...

  • Page 19: Maintenance & Troubleshooting

    It must document the date of inspection, deficiencies determined and the name of the inspector. The date of the next inspection can be read from the inspection plate installed on the system. 667150-52-08 WELDEX FT...

  • Page 20: Inspection And Maintenance Intervals

    During inspection, the system’s air intake must be closed. If the siren sounds, the equipment is in order. The main annual inspection includes: The last test by ESTA is documented on the system!  In collaboration with the ESTA maintenance service  Flow volume measurement ...
  • Page 21 To empty the compressed air tank, activate manual cleaning with the compressed air supply shut off from the control panel, and wait until it has been completed. Get the most from ESTA’s maintenance service! A maintenance contract ensures a long life and top-notch operation for your welding fume filter system.

  • Page 22: Troubleshooting

    11.4 Replacement parts Replacement parts Item No. FT-150 FT-230 30000806 30000805 Filter cartridge 1 Stück 1 Stück Disposal bag 30000575 1 Satz Filter cartridge (= 06000359 10 Stück) Filter pad 01000312 2 qm (in the side panels) WELDEX FT 667150-52-08...

  • Page 23: Replacing The Filter Cartridges

     Sheathe the front row of filter cartridges with a disposal bag. (ESTA item No. 06000359)  Use a cable tie at the top to secure the disposal bag on the filter cartridge.  If an antistatic version of the filter cartridges is used, first also remove the earthing cable from the earthing screw.
  • Page 24  Square socket wrench (for sash lock)  SW 17 open-end wrench (for fastening nuts)  Cable tie  Disposal bag (ESTA item No.: 06000359) Broom or vacuum cleaner (e.g. ESTA EUROSOG industrial vacuum cleaner) Cleaning the filter cartridge in a dismantled state by blowing it out or beating it is not permissible.

  • Page 25: Changing The Filter Pads In The Outlet Grates

    Make sure no air gaps develop between the filter material and the edge of the grate.  Re-insert the outlet grate.  Secure the outlet grate with the fastening screws.  Set the cover caps back onto the fastening screws. 667150-52-08 WELDEX FT...

  • Page 26: Monitoring The Minimum Airflow Volume

    B1 Changing the setting of the monitoring device may only be carried out in consultation with ESTA, by an appropriately trained person. The adjustment must be made at the monitoring equipment of the airflow control. With changes at the monitoring equipment (pressure switch), the adjustment must be made so that the airflow is in all operating conditions within specified tolerance limits.

  • Page 27: Cleaning

    It must never be cleaned with flowing water. 13.1 Pulse-jet cleaning the filter The WELDEX FT has built-in pulse-jet cleaning, a pneumatic method of cleaning the filters. If the vacuum set at the differential pressure switch is reached during operation, filter cleaning takes place.

  • Page 28: Disposal

     Clean the surface around the drawer.  Remove and empty the dust collection container.  Slide the disposal drawer completely into the system.  Insert the latches and tense the drawer upward. Dispose of the collected dust according to local regulations. WELDEX FT 667150-52-08...

  • Page 29: Disposing Of The Welding Fume Extraction Device

    Pins 1 and 2 of the external potential-free contact are connected to the plug (packaged with the device). PIN 3 is reserved for the neutral wire. This is needed only when using special ESTA accessories. Connect the potential equalization to the PIN with the earthing (ground) indicator. (Please...

  • Page 30: Control Filter

    1 unit 150) Filter cartridges (for FT- 01000005 1 unit 230) 15.4 Alternative control (ESTA control unit) 15.4.1 ESTA control unit The system is switched in and out of manual mode by pressing the ON/OFF button. ON/OFF button Main switch...
  • Page 31 15.4.2 Operation through the ESTA control unit Once the system has been turned on at the main switch, it is ready to operate. The extractor fan is not turned on in this case. WELDEX Ready to operate Turning on suction operation with the ON/OFF button Display in suction operation.
  • Page 32 The ordinary user only comes to the operating menu, in which he can operate further functions or call up other information. The other menu items can be accessed only by ESTA production or service. Operating menu: The operating menu is entered using the MODE button.
  • Page 33 Do you really want to activate? -> ON / OFF The precoating function is deactivated only by exceeding the precoating threshold, therefore the new query. MODE button 1. Enter operating menu 2. ESC function for menu entries 667150-52-08 WELDEX FT...
  • Page 34 If the rotating field is wrong, this message appears and the system cannot be operated. The rotating field must be changed. To do this, shut the system off again at the main switch and change the rotating field at the feed line. WELDEX FT 667150-52-08...
  • Page 35 Language selection Change? 1. German 2. English 3. Spanish 4. French This is where the menu language is selected. Software version Software version Vx.xx, x. MONTH 20xx Displays the software version and date. 667150-52-08 WELDEX FT...
  • Page 36 “Settings” is possible by entering a code. For this, a 4-digit access code is needed. When necessary, you can get this access code from ESTA customer service. The access code is valid for at least one and no more than two operating hours after it is entered.
  • Page 37 Settings After “Code Entry” has been activated successfully, the following settings can be made. Do this only with support from ESTA customer service! The following settings are associated with SETTINGS the error messages after them: 1. Type of cleaning 2. upper threshold 3.
  • Page 38 15.4.4 Precoating process on the ESTA control unit  Prepare the precoating powder  Turn the system on at the main switch.  Select the operating menu on the control panel.  Select the precoating function.  Use the ON/OFF key to select the function.
  • Page 39 15.4.5 Maintenance display on ESTA control unit Operating menu: The operating menu is entered using the MODE button. OPERATING MENU 1. Sensor selection 2. Cleaning test 3. Drawer 4. Precoat. Function 5. Operating hours 6. Maintenance 7. Error messages 8. On/Off button tone 9.
  • Page 40 The “Maintenance” menu shows the hours set under “Maintenance interval” minus the operating hours. MODE button Cancel menu function 15.4.6 Possible error messages at the ESTA control unit Motor malfunction Emergency OFF Motor malfunction The motor malfunction entry on the performance unit is activated. The collective malfunction and horn relays are triggered.
  • Page 41 This error message appears if the differential pressure through the filter continues to rise despite cleaning activation. The message must be confirmed with the ON/OFF button. Then cleaning must be started through the operating menu under the “Cleaning test” item. 667150-52-08 WELDEX FT...
  • Page 42 One or more parameters are outside the valid range, and the error prevents suction operation from turning on. In the Settings menu, the factory defaults can be set or completely recreated. This requires the appropriate hardware key or entry of a code. Cancel with the MODE key. WELDEX FT 667150-52-08...
  • Page 43 Press the MODE button to leave the menu again. If the error message still shows up, shut the system off and on again from the main switch. If, after that, the error message still appears, contact ESTA customer service. Calibration data failure...

  • Page 44: Alternative Control (Siemens-Control)

    Once the system has been turned on at the main switch, it is ready to operate. The fan is not turned on in this case. Device ready to operate ESTA Apparatebau Gotenstr. 2-6 Senden 89250 Tel.: 49(0) 7307 804 0 Turn on suction operation with the “System ON” button WELDEX FT 667150-52-08...
  • Page 45 If the rotating field is wrong, this message appears, the horn activates, and the system cannot be operated. The rotating field must be changed. To do this, shut the system off again at the main switch and change the rotating field at the feed line. 667150-52-08 WELDEX FT...
  • Page 46 Once filter cleaning has started, the device must not be opened. After the cleaning cycle is complete, the device can be opened. Precoating function Precoating active Time remaining If the precoating function is active, no cleaning can be done during this time (the time remaining). WELDEX FT 667150-52-08...
  • Page 47 MO 11:15 2012-04-02 3. Press once. This display appears: ESC+C    3. Press at the same time. This display appears: Precoating active Time remaining The precoating function is activated, and the precoating process can be performed. 667150-52-08 WELDEX FT...
  • Page 48 The user has access to the operating menu. Here other functions can be operated, information can be called up, and settings can be made. Other menu items can be accessed only by ESTA production or service. Operating menu: To enter the operating menu, press the button.
  • Page 49 1. Move the cursor to the first position: 2. Choose the number “1”: 3. Move the cursor to the second position: 4. Choose the number “2”: 5. Move the cursor on the unit: 6. Choose the “m” unit for minutes: 667150-52-08 WELDEX FT...
  • Page 50 Confirm the selection using the OK key. DE - German IT - Italian TR - Turkish NL - Dutch RU - Russian ES - Spanish JP - Japanese FR - French EN - English CH - Chinese WELDEX FT 667150-52-08...
  • Page 51 Remaining hours counter, shows in hours how long the system can be operated before maintenance is needed. Total: The device’s operating hour indicator. (active when the motor is on). Reset the maintenance hours counter after maintenance has been completed. 667150-52-08 WELDEX FT...
  • Page 52 This message appears when the vacuum threshold has been exceeded on the separate pressure switch. An acoustic signal sounds. Check the intake side for clogs. If the problem has been resolved, dismiss the error message with the Q key. WELDEX FT 667150-52-08...

  • Page 53: Check Valve At The Suction Opening

    15.6 Check valve at the suction opening The device can be optionally equipped with an automatic check valve at the suction opening. This closes automatically if there is too little volume flow, thus preventing dust from escaping from the opening during off-line cleaning. 667150-52-08 WELDEX FT...

  • Page 54: Representation

    16. Representation WELDEX FT Raw gas suction Fan unit Cleaning unit Control filter (optional) Filter Jet cleaning Filter unit Pre-separator Disposal unit Dust collection container WELDEX FT 667150-52-08...

  • Page 55: Ec - Declaration Of Conformity

    17. EC - Declaration of conformity ESTA Apparatebau GmbH & Co. KG Name of manufacturer: Gotenstraße 2 - 6 Address of manufacturer: 89250 Senden Person in charge of Ramona Pflum documentation: Gotenstr. 2 – 6 89250 Senden We hereby declare that the design of the machine...

  • Page 56: 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 WELDEX FT 667150-52-08...

  • Page 57: 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 667150-52-08 WELDEX FT...

  • Page 58: 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 WELDEX FT 667150-52-08...
  • 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 www.esta.com...

This manual is also suitable for:

Weldex ft-150Weldex ft-230

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