Installation instructions
DDE 1500
DDE 1500
Order No.: 60.000
DDE 1500 Alu-Mix
Order No.: 60.000.001
Do not use this product unless you have
read the operating instructions and understood them.
Translation of Original operating instructions
60000-08-03
General instructions
2
DDE 1500
60000-52-03
Edition notice
Translation of Original operating instructions
Document no.: 60000-08-03
Publishing date: 14.09.2017
Model: DDE 1500 // DDE 1500 Alu-Mix
Article no.: 60,000 // 60,000,001
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 operating 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
60000-52-03
DDE 1500
3
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 ............................................................................................... 6
3. Product description ....................................................................................................... 7
3.1 Product illustration of DDE 1500 ............................................................................ 7
3.2 Functional description ............................................................................................ 8
4. Safety instructions ........................................................................................................ 9
4.1 Hazard categories .................................................................................................. 9
4.2 Symbol explanation ................................................................................................ 9
4.3 General safety instructions ................................................................................... 11
4.4 Fire hazard prevention ......................................................................................... 11
4.5 Preventing mechanical hazards ........................................................................... 12
4.6 Preventing electrical hazards ............................................................................... 13
4.7 Preventing dust hazards ....................................................................................... 14
5. Delivery and commissioning ...................................................................................... 15
5.1 Delivery and transport .......................................................................................... 15
5.2 Connection ........................................................................................................... 16
5.3 Function check ..................................................................................................... 18
5.4 Commissioning ..................................................................................................... 19
5.5 Suction line connection ........................................................................................ 19
5.6 Troubleshooting during commissioning ................................................................ 20
6. Operating instructions ................................................................................................ 20
6.1 Switching the product on ...................................................................................... 20
6.2 Operating the product ........................................................................................... 20
7. Maintenance & troubleshooting ................................................................................. 22
7.1 Maintenance instructions ...................................................................................... 22
7.2 Inspection and maintenance intervals .................................................................. 23
7.3 Emptying the disposal unit.................................................................................... 24
7.4 Locating the collection drawer with the adjusting screw ....................................... 24
7.5 Dismantling the outlet element filter mat .............................................................. 25
7.6 Replacing filter cartridges ..................................................................................... 26
7.7 Cleaning the product ............................................................................................ 28
7.8 Storing the product ............................................................................................... 28
7.9 Rectifying faults .................................................................................................... 29
8. Disposal ....................................................................................................................... 31
8.1 Disposal of collected material ............................................................................... 31
8.2 Disposal of the filter cartridge ............................................................................... 31
8.3 Disposal of the product ......................................................................................... 31
9. Optional equipment ..................................................................................................... 32
9.2 Dust Class H post-filter cassette .......................................................................... 32
10. Declaration of incorporation ...................................................................................... 33
Notes ................................................................................................................................... 35
General instructions
4
DDE 1500
60000-52-03
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
60000-52-03
DDE 1500
5
2. Product identification
2.1 Technical data
We reserve the right to make technical changes.
Item no.
60.000
60.000.002
Type DDE 1500
DDE 1500
DDE 1500 Alu-Mix
Nominal frequency
[Hz]
50
60
50
60
Drive power
[kW]
1,1
Connection voltage
[V]
400 / 460
Nominal current
[A]
2,20
2,45
2,15
2,40
Circuit breaker
[A]
C16A (Automat)
Protection class
IP 55
Max. vacuum
[Pa]
1.950
2.750
1.950
2.750
Max. airflow volume
[m³/h]
1.450
1.700
1.300
1.550
Compressed air connection
bar
4-6
average sound pressure level LpA*
[dBA]
71,5
75,5
64,5
69,5
Dimensions L x W x H
(including filter unit)
[mm]
650 x 710 x 1.455
650 x 710 x 1.860
Ambient temperature
[°C]
540
Rel. humidity
[%]
30 - 70
min. spatial requirement around the
product
Operator's side (front)
Inlet
Outlet
Rear
Top
[mm]
1.000
1.000
1.000
500
1.000
Total weight (including filter unit)
[kg]
160
195
Production year
see type plate
* Using the enveloping surface method DIN EN ISO 3744, measured at minimum volume flow; noise measurement margin of
error approx. 4 dBA
** Custom voltage on request
Product identification
6
DDE 1500
60000-52-03
2.2 Intended application
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:
For permanent connection to a Lissmac processing machine
Only functional as a dust extractor in conjunction with an appropriate filter
unit from the DDE 1500 series.
As a fan unit for a modular dust extraction concept.
For commercial use, such as in industrial enterprises and workshops.
For extraction in individual workplaces.
Only for dry cleaning.
As a central extraction system on dust-generating machinery.
As a central extraction system on chip-generating machinery.
As a central extraction system on machines which produce swarf and chips.
Other applications are considered unintended use. LISSMAC is not liable for
damages due to unintended use!
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 DDE 1500 series.
Do not use or store outdoors or in wet conditions.
Do not change the location of the product during suction operation.
Do not set up or operate in dust/gas-explosive areas.
Do not use in painting operations.
Do not use for the extraction of aluminium or highly alloyed steel dust.
Do not connect to processing machines that may produce active ignition
sparks or hot embers.
Do not suck up liquids.
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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DDE 1500
7
3. Product description
3.1 Product illustration of DDE 1500
Fan unit
Disposal unit
Opening of
intake port
Filter unit
Cleaning unit
Outlet element
Transport lugs
Compressed air
connection
Product description
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DDE 1500
60000-52-03
3.2 Functional description
The fan unit can be combined with different filter units from the DDE 1500 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
Lissmac main system.
Due to the negative pressure produced by the fan, air is sucked in through the
corresponding filter unit. Permanent filters located in the filter unit separate the dust
from the air that is sucked in. The purified air is fed back into the room through the
outlets on the top of the fan unit.
The filter cartridges are manually cleaned with compressed air. Compressed air is
fed into the rotating cleaning device in the product's filter unit via the compressed air
connection. The filters are freed from dust and regenerated as a result of this
cleaning.
The disposal unit attached below the filter collects the dust that has been cleaned
off. The collection drawer is lowered and pulled out for easier disposal of the collected
material.
Safety instructions
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DDE 1500
9
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.
4.2 Symbol explanation
Further information
Reference to legal regulations
Safety instructions
10
DDE 1500
60000-52-03
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.
Do not take in glowing dust or other sources of ignition. Do not use in conjunction
with spark-generating machinery.
Safety instructions
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DDE 1500
11
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
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.
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.
Safety instructions
12
DDE 1500
60000-52-03
4.5 Preventing mechanical hazards
CAUTION
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
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.
The compressed air must be disconnected after use, before moving the device to
another site and before cleaning, maintenance, or replacement or removal of
movable parts.
Safety instructions
60000-52-03
DDE 1500
13
4.6 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!
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!
Any work on the electrical grid and on live components parts may only be
performed by an electrician.
Use only original LISSMAC replacement 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!
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.
All electrical parts must be covered by fixed, securely fastened protective covers
that can be removed only with tools. The product complies with Protection Class I
according to EN 60335.
After use, before moving the product to another site and before cleaning,
maintenance, or replacement or removal of movable parts, switch off the product
at the main switch and render it voltage-free.
Safety instructions
14
DDE 1500
60000-52-03
4.7 Preventing dust hazards
CAUTION
Damage due to dust release
Maintenance, cleaning, repair and emptying work may be done only by
expert personnel.
Wear personal protective equipment.
- Respirator mask (particle filter class P3)
- Protective clothing
- Protective gloves
- Eye protection
Set up locally filtered forced-air ventilation where the product is being
maintained, inspected or cleaned.
Operate the product only with the complete filtration system.
Seal the intake port with a sealing plug so it is dust-tight when transporting.
CAUTION
Damage due to dust build-up in the pipe system
Check the connected piping system regularly for dust deposits.
Observe the minimum air speed required for your application and the
resulting minimum airflow volume.
When opening and emptying the collection drawer, dust
inhalation cannot be ruled out. That is why all servicing, cleaning
and maintenance procedures, including the emptying of the
collection drawer, are only to be performed by specialist
personnel with personal protective equipment.
The people assigned to cleaning work must be instructed with
regard to the aspirated toxic materials. Harm to bystanders and
the environment must be prevented by all means. After the
maintenance has been carried out, the maintenance area must
be thoroughly cleaned.
Delivery and
commissioning
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DDE 1500
15
5. Delivery and commissioning
5.1 Delivery and transport
DANGER
Danger from falling product
Do not walk under heavy loads.
The lifting and transporting equipment must be designed for the weight of
the product.
WARNING
Crushing hazard if the product settles during transport
Secure the product during transport.
Wear safety shoes.
CAUTION
Risk of damaging the product due to improper transport.
Do not push the product over the floor if it does not have any rollers.
Use only suitable lifting and transport equipment (such as a forklift or lift
truck) when transporting the product to its set-up location.
Watch out for the centre of gravity – which is not in the middle – when
lowering the machine.
Make sure the floor has adequate weight capacity and can be properly
driven on when transporting the product.
Products with feet or recesses for fork-lift trucks must always be dowelled
to the floor.
Upon delivery inspect the product for transportation damage. Damage
determined must be reported and documented immediately.At delivery,
the product is fastened to a pallet.
Remove the protective cover and floor securing devices.
Check the delivery is complete
Pay attention to the weight of the product and its centre of gravity
during all transport work.
Hang the product using sling gear (e.g. a lifting belt, round sling)
at the positions provided, lift it from the pallet and set it down
immediately on the floor next to the pallet.
Lift the product from the pallet using a forklift at the positions
provided and set it down immediately on the floor next to the
pallet.
Delivery and
commissioning
16
DDE 1500
60000-52-03
5.2 Connection
5.2.1 Electrical connection
DANGER
Electric shock from high voltages
Avoid damage to the power cable caused by running over, crushing or
straining it.
Regularly check the power cable for damage and wear.
Do not start up if damage has been found on the power cable!
Any work on the electrical grid and on live components parts may only be
performed by an electrician.
Use only original replacement parts.
Before establishing cable connections between the product and the mains, it is
essential to check that the operating voltage specified on the rating plate matches
that of the mains.
DANGER
Electric shock from high voltages
Follow the safety rules for working with electrical products!
The product must be secured from being switched on again while work is
being carried out on it.
Place the device horizontally on an even surface as close as possible to the dust
source.
Connection to the building's power supply is made at the installation location.
DDE 1500
Mains (standard)
3~PEN /
3~PE+N
Three-phase current
400V/50Hz 3N~
Fuse
[Amp.]
C16A (circuit breaker)
* Custom voltage on request; observe the specifications on the rating plate.
Delivery and
commissioning
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DDE 1500
17
5.2.3 Pneumatic connection
Compressed air is required for the manual rotary cleaning of the filter elements in
the filter unit. Connect oil and water-free compressed air to ensure operational
safety and machine availability.
Connection to the compressed air supply (compressor) is made at the installation
location.
DDE 1500
Compressed air quality (ISO 8573-
1:2010-04)
Class 3.2.2
Pressure
[bar]
4 - 6
Connection-ø
['']
¼ (ø9mm)
5.2.4 Activation operations for motors:
Motors with high output without frequency converters should be not be switched on
and off within a short period of time too frequently. Otherwise, electrical
components could overload as a result. Please observe the table for activation
operations:
Motor output (kW)
Activation operations per hour
1 – 4
Up to 8 starts
4 – 7,5
Up to 6 starts
7,5 – 15
Up to 4 starts
15 – 30
Up to 3 starts
From 30
Electronically controlled overrun time
Delivery and
commissioning
18
DDE 1500
60000-52-03
5.3 Function check
Before the product is first used, a function check must be performed.
Operate the main switch on the main system to carry out a functional test of the
product.
5.3.1 Rotation direction monitoring
DANGER
Electric shock from high voltages
Any work on the electrical grid and on live components parts may only be
performed by an electrician.
When the direction of rotation is incorrect, the product becomes impermissibly hot,
the volume increases, the airflow volume falls, and the product’s suction
performance suffers. Damage to the product cannot be ruled out.
After first switching on the product, you should check that the fan rotor’s direction
of rotation is correct.
1. Switch on the product using the main switch on the connected system.
2. Check the direction of rotation of the fan impeller.
3. If the direction of rotation is incorrect, have phases L1 and L3 reversed by
an electrical technician.
4. Switch the connected main system on again.
5. The product is ready for operation.
Delivery and
commissioning
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DDE 1500
19
5.4 Commissioning
Use original accessories.
Once a functional inspection has been completed, the connection is made to the
processing apparatus that is to be extracted.
1. Disconnect the product from the compressed air supply.
2. Switch the product off at the connected main system.
3. Place the product on an even surface as close as possible to the work
station.
4. Switch the product on again at the connected main system.
5. Connect the compressed air.
5.5 Suction line connection
Connect the processing machine to be vacuumed to the filter unit's
intake port through a pipeline.
For a suction line, use
a pipeline with a length of 3 m that meets the national
requirements for this application.
an appropriate pipe (wrap fold) that meets the national
requirements for this application.
approved adapters for short diameter on the connection
piece
If the pipe diameter is increased or the pipeline lengthened, it cannot be
guaranteed that no dust deposits will collect in the pipeline.
Observe the minimum air speed necessary for your application. Regularly check
the pipeline for dust deposits.
Operating instructions
20
DDE 1500
60000-52-03
5.6 Troubleshooting during commissioning
Fault
Possible cause
Possible solution
The motor shuts down
before reaching the
operating speed.
The switching products
present (main system) are
incorrectly set up or are
unsuitable.
Check the direction of
rotation and have phases
reversed by an electrical
technician if necessary.
Motor power consumption
is too high.
Direction of motor rotation
is incorrect.
The phases in the mains
power cable may only be
changed by an electrical
technician.
The desired air quantity is
not reached
The supply cable's
preliminary fuse has
tripped.
Motor was switched on/off
too often within a short
period of time.
Please consult the
"Activation operations for
motors" table.
6. Operating instructions
6.1 Switching the product on
Before starting work, check that the product is in a proper and safe condition.
The compressed air supply (4-6 bar) must be connected.
Switch the product on at the connected main system.
6.2 Operating the product
After connecting the suction hose to the dust source:
1. Switch the product on at the main system.
2. Start processing machine / extraction element.
3. Start the processing operation.
The location of the product must not be changed during operation.
When finishing the processing operation:
1. End the processing operation.
2. Switch off processing machine / extraction element.
3. Take the product out of operation using the connected main system.
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