Lissmac WDE 4500 ALU MIX Owner's manual

DIE GANZE WELT DER ABSAUGTECHNIK

01&3"5*0/."/6"-

WDE 500 // 7500 ALU-MIX

8FUTFQBSBUPS

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

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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

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.

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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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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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

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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

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WDE 4500 Alu-Mix

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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

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2.2 Intended application

2.2.1 Ambient conditions

Ambient temperature

[°C]

540

Rel. humidity

[%]

30 - 60

min. spatial requirement around the

product

Operator's side (front)

Inlet

Outlet

Rear

Top

[mm]

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

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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 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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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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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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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

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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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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.

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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.

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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.

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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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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

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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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Lissmac WDE 4500 ALU MIX Owner's manual

Lissmac WDE 4500 ALU MIX Owner's manual

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