DIE GANZE WELT DER ABSAUGTECHNIK
01&3"5*0/."/6"-
WDE 500 // 7500 ALU-MIX
8FUTFQBSBUPS
Welcome to the wide world of extraction technology
With the purchase of an ESTA product you have chosen a quality
product which has been designed to the current state of the art.
ESTA products provide clean air to the work place and
consequently guarantee better quality, longer machine running
times and above all, provide healthier working conditions.
We will be pleased to answer at any time your questions on any
aspect of extraction technology.
Your team at
ESTA Apparatebau GmbH & Co. KG
THE WORLD OF EXTRACTION
Operating manual
WDE 4500 // 7000 Alu-Mix
WDE 4500 Alu-Mix (order no.: 05.005)
WDE 7000 Alu-Mix (order no.: 05.006)
and variations
Do not use this product unless you have
read the operating manual and understood them.
Translation of original operating manual
05005-08-01
General instructions
2
WDE 4500 Alu-Mix
05005-52-01
Edition notice
Original operating manual
Document no.: 05005-08-01
Publishing date: 29/05/2017
Model: WDE 4500 Alu-Mix // WDE 7000 Alu-Mix
Article no.: 05005 //05006
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
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.
The warranty can only be accepted if the following conditions are met:
- Professional transport
- Professional assembly, commissioning and operation using these installation instructions.
Verifiable compliance with the prescribed maintenance intervals.
- Operation of the product with conveyed media having the specified chemical and physical
properties.
- Immediate reporting of damage to the manufacturer.
- Exclusive use of genuine replacement parts.
- Structural modifications to the original condition only to be carried out with the agreement and
written approval of the manufacturer.
General instructions
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WDE 4500 Alu-Mix
3
Table of contents
1. General instructions ........................................................................................................ 4
1.1 Target group ............................................................................................................. 4
1.2 Tips .......................................................................................................................... 4
2. Product identification ...................................................................................................... 5
2.1 Technical data ............................................................................................................. 5
2.2 Intended application ................................................................................................. 7
3. Product description ......................................................................................................... 9
3.1 Product illustration of WDE 4500 / 7000 Alu-Mix ...................................................... 9
3.2 Functional description ............................................................................................ 10
4. Safety instructions ........................................................................................................ 11
4.1 Hazard categories .................................................................................................. 11
4.2 Symbol explanation ................................................................................................ 11
4.3 General safety instructions ..................................................................................... 13
4.4. Fire hazard prevention ........................................................................................... 13
4.5 Preventing explosive hazards ................................................................................. 14
4.6. Preventing mechanical hazards ............................................................................. 16
4.7. Liquid hazard prevention ........................................................................................ 17
4.8 Preventing electrical hazards ................................................................................. 18
4.9. Preventing dust hazards ......................................................................................... 20
5. Delivery and commissioning ........................................................................................ 21
5.1 Delivery and transport ............................................................................................ 21
5.2 Connection ............................................................................................................. 24
5.3 Function check ....................................................................................................... 27
5.4 Commissioning ....................................................................................................... 29
5.5 Suction line connection .......................................................................................... 31
5.6 Troubleshooting during commissioning .................................................................. 32
6. Operating instructions .................................................................................................... 34
6.1 Switching the product on ........................................................................................ 34
6.2 Operating the product ............................................................................................. 34
7 Maintenance & troubleshooting ...................................................................................... 36
7.1 Maintenance instructions ........................................................................................ 36
7.2 Inspection and maintenance intervals .................................................................... 38
7.3 Replacing the filter mat on outlet element .............................................................. 39
7.4 Cleaning the product .............................................................................................. 40
7.5 Cleaning the droplet separator .................................................................................. 40
7.6 Cleaning and maintenance of the fan ........................................................................ 41
7.7 Storing the product ................................................................................................. 42
7.8 Remedying faults .................................................................................................... 42
8. Disposal ............................................................................................................................ 45
8.1 Changing and disposing of water ........................................................................... 45
8.2 Disposal of collected material ................................................................................. 46
8.3 Disposal of the product ........................................................................................... 46
10 EC-/EU-Declaration of Conformity................................................................................. 47
Notes ..................................................................................................................................... 49
Notes ..................................................................................................................................... 50
Notes ..................................................................................................................................... 51
General instructions
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WDE 4500 Alu-Mix
05005-52-01
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 the
substance(s) for which it is to be used, including the procedure for safe disposal of
the collected material. Responsibilities must be clearly established on site for the
following
Assembly
Commissioning
Operation
Maintenance and repairs
Disposal
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 receive.
Check the completeness of the documents and pay attention to their content.
Product identification
05005-52-01
WDE 4500 Alu-Mix
5
Further documents are available on top of these instructions. You can request any
documents required from LISSMAC.
additional maintenance instructions for the filter unit filter
Additional maintenance instructions for the filter unit: disposal
Instructions on optional equipment
2. Product identification
2.1 Technical data
We reserve the right to make technical changes.
Item no.
05.005
Model
WDE 4500 Alu-Mix
Nominal frequency
[Hz]
50
60
Drive power
[kW]
5,5
Connection voltage
[V]
400
460
Nominal current
[A]
5.0
6.5
Circuit breaker
[A]
C16A (circuit breaker)
Protection class
IP 55
Max. vacuum
[Pa]
3,800
xx
Air flow volume effective
[m³/h]
5,000
xx
Water tank
[litres]
xx
average sound pressure level LpA*
[dBA]
xx
Dimensions W x D x H
[mm]
1.350 x 4.220 x 1.410
Total weight (including filter unit)
[kg]
xx
Production year
See model plate
*The measurement surface sound pressure level was measured according to DIN EN ISO 3744 in an open area, at maximum volume flow, at
a 1-m distance from the surface of the device, at a height of 1.6 m above ground. The sound power level was calculated from the
measurement surface sound pressure level and the device dimensions in accordance with DIN EN ISO 3744. Noise measurement margin of
error approx. 4 dBA.
Product identification
6
WDE 4500 Alu-Mix
05005-52-01
We reserve the right to make technical changes.
Item no.
05.006
Model
WDE 7000 Alu-Mix
Nominal frequency
[Hz]
50
60
Drive power
[kW]
3
Connection voltage
[V]
400
460
Nominal current
[A]
5.0
6.5
Circuit breaker
[A]
C16A (circuit breaker)
Protection class
IP 55
Max. vacuum
[Pa]
3,800
xx
Air flow volume effective
[m³/h]
5,000
xx
Water tank
[litres]
xx
average sound pressure level LpA*
[dBA]
xx
Dimensions W x D x H
[mm]
1.350 x 4.220 x 1.410
Total weight (including filter unit)
[kg]
xx
Production year
See model plate
*The measurement surface sound pressure level was measured according to DIN EN ISO 3744 in an open area, at maximum volume flow, at
a 1-m distance from the surface of the device, at a height of 1.6 m above ground. The sound power level was calculated from the
measurement surface sound pressure level and the device dimensions in accordance with DIN EN ISO 3744. Noise measurement margin of
error approx. 4 dBA.
Product identification
05005-52-01
WDE 4500 Alu-Mix
7
2.2 Intended application
2.2.1 Ambient conditions
Ambient temperature
[°C]
540
Rel. humidity
[%]
30 - 60
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:
The WDE 4500 / 7000 Alu-Mix product is equipped with a filter in dust class “H”
(dust that is hazardous to health). For the separation of dust with an exposure limit
of more than 0.1 mg/m³. Cleaned air can be returned in the work room.
for permanent connection to an upstream LISSMAC processing machine
Only functional as a dust extractor in conjunction with an appropriate filter
unit from the WDE 4500 / 7000 Alu-Mix series.
As a fan unit for a modular dust extraction concept.
For commercial use, such as in industrial enterprises and workshops.
Only for installation on conductive foundation or breccia (e.g. rock, concrete,
wood).
for extraction in individual workplaces.
For the separation of dry, free-flowing, flammable, explosive and non-
conductive dust/air mixtures in dust-explosive zone 22.
For the extraction of dusts with a known low minimum ignition energy (MIE
<1mJ).
Only in combination with electrically conductive pipe or hose lines
For the extraction of aluminium or highly alloyed steel dust.
As a central extraction system on machines that produce dust from swarf,
chips and brushing.
Other applications are considered unintended use. LISSMAC is not liable for
damages due to unintended use!
Product identification
8
WDE 4500 Alu-Mix
05005-52-01
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 operate without an appropriate filter unit from the WDE 4500 / 7000
Alu-Mix series.
Do not use or store outdoors or in wet conditions.
Do not set up or operate in dust-explosive zones 20, 21 and 22.
Do not use to extract different dusts without first thoroughly cleaning the
pipeline.
Do not change the location of the product during the extraction operation.
Do not set up or operate in gas-explosive zones 0 and 1.
Do not extract dust from sources for which the 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 aggressive gases.
Do not suck up any readily flammable or glowing 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.
Product description
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WDE 4500 Alu-Mix
9
3. Product description
3.1 Product illustration of WDE 4500 / 7000 Alu-Mix
Fan unit
Droplet separator
with wire mesh filter
Opening of intake port
Water tank
Water connection
Outlet element
H-filter
Switch box
Transport lugs
Inspection opening
Drain valve
Fire extinguisher opening
Fill level control
Product description
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WDE 4500 Alu-Mix
05005-52-01
3.2 Functional description
The fan unit can be combined with different filter units from the WDE 4500 / 7000
Alu-Mix series. It is equipped with a three-phase motor which drives a radial fan. The
fan unit is supplied with or disconnected from the required power via the connection
to the upstream LISSMAC main system.
Potential risk of explosion due to accumulation of aluminium dust. The interior of
the WDE 4500 / 7000 Alu-Mix is protected against the formation of sparks by the
explosion-protected fan and earthed components.
The operator must ensure that no such deposits accumulate around the system, in
part through adequate ventilation of the room!
As a result of the vacuum generated by the fan, air is sucked in through the pipeline
or a suitable conductive hose connection via the filter unit. The air is cleaned by
swirling the dust together with water at well as by centrifugal deposition. The purified
air is fed back into the room through the outlet element on the top of the fan unit.
There is water in the lower part of the swirl chamber. The extracted air flows through
this chamber at high speed and swirls intensively together with the water. As a result,
the dust carried in by the air is wetted with water and bound in the water as silt. The
water-bound dust sinks into the collection container. For easier disposal and
maintenance, a drain valve and inspection opening are fitted on the collection
container. The drained water is stored in suitable containers and disposed of
according to local regulations.
Sensors check the water level and ensure an adequate amount of water and
maximum fill level. The product is automatically filled with water via the inlet valve,
which should be connected to a local water supply, until the maximum water level is
reached.
Between the fan and the swirl chamber there is a wire mesh filter, which serves as a
droplet separator and extinguishes any sparks. The droplet separator separates any
stirred up droplets and sparks that are still in the air current in the inner housing.
Safety instructions
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WDE 4500 Alu-Mix
11
4. Safety instructions
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.
NOTE
Information on possible damage to the product and the environment.
Non-observance may cause material damage.
4.2 Symbol explanation
Information on explosive hazards.
Reference to legal regulations
Safety instructions
12
WDE 4500 Alu-Mix
05005-52-01
4.2.1 Symbols on the product
Before commissioning, read and observe the installation instructions and safety
instructions (per ISO 11684)
1. Switch the product off.
2. Wait 5 minutes.
3. Then pull out the collection
drawer or open the product.
Direct access to the source of the fire with suitable extinguishing agents is
possible via the fire extinguishing openings. These openings are not intended to
be used as inspection openings and are only to be used in the event of a fire to
reduce the fire quicker.
The product is designed for use with toxic dusts.
When working on an open devices (maintenance, cleaning,
servicing) the operator is to take special protective measures
including the wearing of personal protective equipment. The
complete filtration system consisting of pre-filter and main
filter must always be in operation when the product is being
operated.
The main filter element may not be subject to reuse once it
has been removed from the product.
Safety instructions
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WDE 4500 Alu-Mix
13
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.
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.
14
WDE 4500 Alu-Mix
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4.5 Preventing explosive hazards
DANGER
Risk of explosion
Non-observance of the ATEX safety information may lead to a fatal
explosion (of dust and/or gas).
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.
The product is not suitable for the extraction or aspiration of explosion-
hazardous or equivalent substances in the sense of
§ 1 of the German Explosives Act, of liquids, or of mixtures of flammable
dusts with liquids.
DANGER
Risk of explosion from installing and operating in a prohibited zone
Installation and operation is only permitted in dust-explosion zone 2/22!
Installation and operation in dust-explosion zones 20 and 21 is prohibited!
Installation and operation in explosive gas zones 0 or 1 is not permitted.
The efficacy of the product under a maximum hazardous substance load
must be verified.
DANGER
Risk of explosion due to use of unauthorised spare and accessory parts
Only use original spare parts and plug devices in accordance with EN
60079-14.
05005-52-01
WDE 4500 Alu-Mix
15
DANGER
Risk of explosion from opening the product in an explosive zone
Perform maintenance, cleaning and servicing work for which the product
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
product 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 product 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.
DANGER
Risk of explosion from the intake of sources of ignition
Ensure that no ignition sources can be sucked in.
The following potential sources of ignition must be excluded from the
process:
- Suction of flames and hot gases
- Electrical compensating currents, cathodic corrosion protection
- Suction of liquid mist and vapours
- High-frequency electromagnetic waves
- 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
DANGER
Risk of explosion due to extraction of different dusts into the same pipe
Before extraction, thoroughly clean the pipe of residual dust or replace it.
DANGER
Risk of explosion due to dusty atmosphere
To prevent an explosive dust atmosphere in the suction pipe, the dust load
must be no less than 30g/m³ (LEL).
The dust container must be cleaned and refilled each time a new type of
dust is handled.
16
WDE 4500 Alu-Mix
05005-52-01
4.6. Preventing mechanical hazards
DANGER
Danger caused by product tipping over
Always lift the product vertically during loading and assembly work.
Secure the assembly area and mark it out (e.g., with barrier tape).
Only transport the product with suitable and approved means of lifting and
transport.
Do not stand under suspended loads.
WARNING
Injuries from crushing
Make sure that the surface can be driven on, is level and sufficiently load
bearing.
Do not park on a sloping floor.
Always wear safety shoes when moving the device!
Watch out for pipe or hose connections and other valves, or disconnect if
required.
WARNING
Tipping hazard due to loose or open covers and components
Keep covers closed during operation!
WARNING
Crushing hazard due to loose or open covers during operation
Keep covers tightly closed during operation!
WARNING
Risk of tripping due to inattentiveness and when the collection drawer is pulled out.
Always pay attention to the local accident prevention regulations.
Keep a distance from the product when you are not working with it.
Always push the collection drawer back in after visual inspection and
emptying.
WARNING
Risk of falling due to improper handling of the transport lugs.
Always pay attention to the local accident prevention regulations.
Only attach the permitted transport aids and lifting tools to the transport lugs.
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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WDE 4500 Alu-Mix
17
4.7. Liquid hazard prevention
CAUTION
Risk of injury due to slipping on wet surfaces
Pay attention to leaking water and other unwanted leaks.
Wear non-slip safety shoes.
Adequately secure work areas with wet surfaces against unauthorized
access.
WARNING
Difficult working conditions and corrosion due to high humidity and condensation
Ensure adequate ventilation of the work area
Direct exhaust air outdoors
A secure connection to the local water supply must be established on site. Before
disconnecting the water supply, the water pipe must be depressurised.
Safety instructions
18
WDE 4500 Alu-Mix
05005-52-01
4.8 Preventing electrical hazards
DANGER
Electric shock from high voltages
Follow the safety rules for working with electrical products!
Secure the product from being switched on.
Render the product voltage-free by switching off the main system!
The connection may only be made when the mains is voltage-free.
Any work on the electrical grid and on live components parts may only be
performed by an electrician.
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!
The electrical supply cable must be protected against damage and suitably
dimensioned for the power consumption.
The safety devices (motor protection relay, earthing resister, etc.) must be
checked and adjusted.
Any work on the electrical grid and on live components parts may only be
performed by an electrician.
Only use conductive original spare parts.
DANGER
High-voltage electric shock when working on the running product
Switch off the product via the main system and secure it from being switched
on again.
Render the product voltage-free by switching off the connected main system!
Conductive extraction equipment (e.g., extraction hoods on machines) and
conductive parts of processing machines (e.g. devices in protection class II)
that are not earthed (grounded) by the dust extractor must be earthed in
some other way to prevent electrostatic charging.
Any work on the electrical grid and on live components parts may only be
performed by an electrician.
DANGER
Residual hazard from loose or open covers
Keep covers closed during operation!
Any work on the electrical grid and on live components parts may only be
performed by an electrician.
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