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
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
4
DDE 3200
05001-52-02
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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DDE 3200
5
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]
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
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
6
DDE 3200
05001-52-02
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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DDE 3200
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.
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
10
DDE 3200
05001-52-02
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
12
DDE 3200
05001-52-02
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
05001-52-02
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
14
DDE 3200
05001-52-02
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
16
DDE 3200
05001-52-02
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
18
DDE 3200
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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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