Lissmac DDE 3200 Owner's manual

THE WORLD OF EXTRACTION

INSTALLATION INSTRUCTION

DDE 3200

Stationary deduster

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

DDE 3200

DDE 3200 Order No.: 05,001

and variations

Do not use this product unless you have

read the operating manual and understood them.

Translation of original operating manual

05001-08-02

General instructions

2

DDE 3200

05001-52-02

Edition notice

Original operating manual

Document no.: 05001-08-02

Publishing date: 14.09.2017

Model: DDE 3200

Article no.: 05001

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 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

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DDE 3200

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 DDE 3200 .................................................................................. 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

4.8 Preventing noise hazards .......................................................................................... 15

5. Delivery and commissioning ........................................................................................ 16

5.1 Delivery and transport ............................................................................................ 16

5.2 Connection ............................................................................................................. 18

5.3 Suction line connection .......................................................................................... 21

5.4 Function check ....................................................................................................... 22

5.5 Commissioning ....................................................................................................... 24

5.6 Troubleshooting during commissioning .................................................................. 26

6. Operating instructions .................................................................................................... 26

6.1 Switching the product on ........................................................................................ 26

6.2 Operating the product ............................................................................................. 26

6.3 Jet-pulse cleaning .................................................................................................. 27

7. Maintenance & troubleshooting ................................................................................... 29

7.1 Maintenance instructions ........................................................................................ 29

7.2 Inspection and maintenance intervals .................................................................... 30

7.3 Emptying the disposal unit...................................................................................... 31

7.4 Locating the collection drawer with the adjusting screw ......................................... 32

7.5 Dismantling the outlet element filter mat ................................................................ 33

7.6 Replacing filter cartridges ....................................................................................... 34

7.7 Cleaning the product .............................................................................................. 36

7.8 Storing the product ................................................................................................. 36

7.9 Remedying faults .................................................................................................... 37

8. Disposal ............................................................................................................................ 39

8.1 Disposal of collected material ................................................................................. 39

8.2 Disposal of the filter cartridge ................................................................................. 39

8.3 Disposal of the product ........................................................................................... 39

9. Optional equipment ......................................................................................................... 40

9.1 Retrofit Kit H filter ................................................................................................... 40

10 EC-/EU-Declaration of Conformity................................................................................. 41

Notes ..................................................................................................................................... 42

Notes ..................................................................................................................................... 43

Notes ..................................................................................................................................... 44

Notes ..................................................................................................................................... 45

General instructions

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DDE 3200

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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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2. Product identification

2.1 Technical data

We reserve the right to make technical changes.

Item no.

05.001

Model

DDE 3200

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 (Automat)

Protection class

IP 55

Max. vacuum

[Pa]

2.500

3.400

Max. airflow volume

[m³/h]

3.000

3.500

Compressed air connection

bar

4-6

average sound pressure level LpA*

[dBA]

74,5

77,5

Dimensions L x W x H

(including filter unit)

[mm]

900 x 960 x 2.860

Total weight (including filter unit)

[kg]

500

Filter type

Filter cartridge

Number of filter elements

[Number]

2

Filter area

[m²]

10

Collection drawer

[l]

2x 40

Intake port ø

[mm]

180

Dimensions L x W x H (only filter

unit)

[mm]

960 x 900 x 2,860

Ambient temperature

[°C]

540

Rel. humidity

[%]

30 - 70

min. spatial requirement around the

product

Operator's side (front)

Inlet

Outlet

Rear

Top

[mm]

1,000

500

1,000

Production year

See model 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

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DDE 3200

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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 3200 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 dust from swarf,

chips and brushing.

Other applications are considered unintended use. ESTA 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 3200 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 3200

7

3. Product description

3.1 Product Illustration DDE 3200

Fan unit

Disposal unit

Opening of intake port

Filter unit

Cleaning unit

Outlet element

Fire extinguisher

opening

Switch box

Transport lugs

Product description

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DDE 3200

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3.2 Functional description

The fan unit can be combined with different filter units from the DDE 3200 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

outlet element on the top of the fan unit.

An automatic post-cleaning function (Jet-pulse) is integrated in the product. The

filters are freed from dust and regenerated as a result of this cleaning. The cleaning

process starts automatically, after a waiting period, if the device is switched off via

the external start/stop (automatic mode) or the STOP button (manual operation).

Jet-pulse cleaning cleans the filter cartridges with compressed air fed into the

product.

The Jet-pulse cleaning system can be activated manually by pressing the

button.

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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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

Reference to legal regulations

Safety instructions

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DDE 3200

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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.

Do not take in glowing dust or other sources of ignition. Do not use in conjunction

with spark-generating machinery.

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.

Safety instructions

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DDE 3200

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

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.

Safety instructions

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DDE 3200

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4.5. Preventing mechanical hazards

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

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

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DDE 3200

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 ESTA 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

via the connected main system and render it voltage-free.

Safety instructions

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DDE 3200

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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.

Safety instructions

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DDE 3200

15

4.8 Preventing noise hazards

CAUTION

Danger of hearing damage from release of compressed air impulses when filter

elements are being cleaned

 Keep product covers closed.

 Wear hearing protection.

 Only open the product with the compressed air tank de-pressurised.

To do this:

- Switch off suction on the control unit,

- Wait for the automatic post-cleaning to end,

- Disconnect the compressed air supply

- Empty the compressed air tank – via the control system if necessary.

 Only open the product when the system is switched off.

To do this:

- Turn the product off at the main switch.

- Cut off the power supply.

The manometer attached to the compressed air tank is used for monitoring the

pressure in the tank.

After use, before moving the product to another site and before cleaning,

maintenance, or replacement or removal of movable parts, disconnect the

compressed air.

Delivery and

commissioning

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DDE 3200

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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

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.

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.

NOTE

 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.

Delivery and

commissioning

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DDE 3200

17

5.1.1 Removing the product from the palette

The product is delivered fastened to a pallet

Upon delivery inspect the product for transportation damage. Damage determined

must be reported and documented immediately.

Permitted sling gear:

 Lifting belt

 Round sling

Permitted lifting gear:

 Crane

1. Unpack the product

2. Remove the protective cover and floor securing devices.

3. Check the delivery is complete

4. Pay attention to the weight of the product and its centre of gravity

during all transport work.

5. Using the transport lugs provided, attach the product to an

approved sling device (e.g. lifting belt, round sling).

6. Lift the product from the pallet and set it down on the floor adjacent

to the pallet.

Delivery and

commissioning

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05001-52-02

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 ESTA replacement parts.

 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.

NOTE

 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.

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 3200

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.

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Lissmac DDE 3200 Owner's manual

Lissmac DDE 3200 Owner's manual

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