Operating manual AIRBOX
Contents
1.2. After an extended operation period the filter pores can be clogged by extremely fine dust The filter must be replaced with a new one If possible filter replacement must be done when there is no work going on Used filters and the accessories used must be discarded in compliance with local regulations in a closed dustproof plastic bag Airbox 99300 52 00 ESTA Cleaning filter replacement d Filter replacement 1 Lock the castors 2 To replace the filter loosen the two screws on the left side of the AIRBOX to remove the filter cover Attention The filter cover can be removed completely 3 Loosen the screw until the filter cassette and the fibreglass mat on top of it go down 4 Now both filters can be removed with a light pull on the handle Then depending on the degree of contamination you can replace the fibreglass mat or the filter cassette as well 5 After inserting the new filters tighten the screw under point 3 until the filter cassettes return to their initial position Now once you screw the filter cover on the AIRBOX is ready to run 99300 52 00 Airbox 13 N A Disposal ESTA 10 Disposing of the device The people assigned to disposal work must be instructed on the aspirated toxic materials and wear a breathing protection mask with a class P3 particle filter as well as protective clothing All distractions by uninvolved persons must be prevented o Before disposing of the device
3. Aspiration of welding fumes is not permissible with welding of oil moistened parts The device must not be used or stored outdoors or under wet conditions Other applications are considered unintended use ESTA is not liable for damages due to unintended use ESTA sets up the welding fume filter according to the operator s information Airbox 7 7 Technical data ESTA 6 Technical data and description 6 1 AIRBOX ax vacuum e Fibreglass mat cassette filter Nominal frequency incl exhaust arm 30 300 x 300 oee model plate NN E 6 2 Functional description The AIRBOX is equipped with 1 25 kW motor that drives a radial fan The device is turned on and off with using the green main switch The vacuum created by the fan draws air through the exhaust arm connected to the intake port The permanent filters in the filter housing separate the dust that is in the exhausted air The purified air is guided back into the room through the exhaust vents Diminishing suction performance signals that the filters have clogged You can order new filters from ESTA s replacement part service Y ESTA replacement part service 49 0 7307 804 831 8 Airbox 99300 52 00 ESTA f le El 99300 52 00 Delivery installation and start up lt Delivery installation and start up 7 1 Delivery and transport The AIRBOX is delivered on a pallet and the exhaust arm packed in a box After the protective cove
4. ESTA Operating manual CE AIRBOX Item No 55 300 A Do not use this device unless you have read the user manual and understand it Original version of the German operating manual 55300 08 00 elec oe bp N Symbols Warnings and safety instructions Electrical current hazard Note Reference to ESTA customer service Reference to legal regulations Airbox ESTA 99300 52 00 1 ESTA Contents Contents GONIENIS un nee ee ed ed ee ee anal 3 1 General safety NOLES cuida 4 2 Preventing mechanical hazards occconnccnnncccncconncconacconnnccnanncnancnnancnnanrnnanrenanrenanrenanennanennanos 6 3 Preventing electrical Nazarala 6 4 Preventing dust hazards iii 7 GNE e 0 USE 00 AA 7 6 Technical data and descriptos aid dida 8 BI AMBOS iia 8 8 2 Fl nellonal desenplionse see 222 A a as 8 7 Delivery installation and start up uu22u00 00000an00nan0nnanunnanunnnnunnanunnanunnanunnanunnanunnanunnnnen 9 Tal Delivery and transport unse ee ee ea 9 7 ZA STANS UO LT zn ne ee ee 9 OS Sl Usina Ei 10 8 Maintenance and troubleshooting u uu an000an00nannonnununnanunnnnunnnnunnnnnnnnnunnununnnnennnn 10 8 1 MeantenanecsIaStUCUONS RT m 10 8 2 Maintenance IM Sa aa 11 8 3 FoOuUDIESROOUNO pan dls 11 9 Cleaning filter replacement u uueen nn 12 miserie T S SLE 13 10 Disposing OT ING CEVICE cursis Co d ro DE 14 11 Device QlIagram RE 15 T2 De
5. With free room ventilation the incoming airflow must equal the room volume every hour This means that the rate of air replacement must be once per hour Incoming air flow m h room volume mf air replacement rate 1 h Example When the device is operating at the nominal airflow volume of 1 100 mY h the same volume of fresh air must be fed in This occurs with natural ventilation if the volume of the work room is 1 100 m e g 458 m surface with a 2 4 m ceiling height Airbox 99300 52 00 ESTA gt gt gt kl gt 99300 52 00 Safety instructions The exhaust arm s detection device must be tracked in consideration of the suction range of about 200 mm and of exploitation of the welding site s welding fume movement Make sure that the power cable does not become damaged by being run over compressed pulled etc The power cable must be examined regularly for signs of damage or ageing The device must not be used if damage to the power cable is determined The power cable and plug must be replaced only by an appropriately trained electrical specialist For the power supply and the device s power cords only original ESTA replacement parts must be used This guarantees that they are spray proof according to applicable standards and have the necessary mechanical strength The power cord must be plugged in only after the welding fume filter has been successfully set up at its place of use After use before m
6. claration 01 CONIOrMIlVe nenne een ana da as aaa nahe Feel 16 NOTO EE 17 Mfoj llfee X 18 jp Il t 19 jf lp aa ae 20 99300 52 00 Airbox 3 oafety instructions ESTA 1 General safety notes Before operation all persons who are to use the device or perform maintenance on it must be provided with information instructions and training in using the device and on the substances for which it is to be used including the procedure for safe disposal of the collected material Responsibilities must be clearly established for the following Installation Start up Operation Maintenance and repair The device must be used only by persons who have been instructed in its handling and are explicitly authorized to use it Always keep the operating manual at the place where the device is being used so that it can be seen by personnel at all times The device must be used only to exhaust welding fumes No liquids aggressive gases easily flammable materials or glowing particles such as hot embers may be aspirated Use of the device when welding oil covered metals is prohibited Fire hazard The device must not be used or stored outdoors or under wet conditions Only original ESTA replacement parts must be used use of other products will void the warranty During exhaust the volume flow returned from the device into the room must be no more than 5096 of incoming air
7. intenance instructions For maintenance by qualified personnel the device must be opened cleaned and inspected at the given locations as well as possible without any hazard being posed to maintenance personnel or other persons Proper precautions must be taken before cleaning and removal of wearing parts This includes locally filtered forced air ventilation in the area in which the device is being maintained and proper personal protective gear During maintenance or repair work all soiled objects that can no longer be adequately cleaned must be disposed of Such objects must be disposed of in an impermeable bag in compliance with applicable regulations for disposal of such refuse Airbox 99300 52 00 ESTA 99300 52 00 Maintenance v2 If the device is not needed in its location of use for a long time it must be stored in a dry room The temperature should not be below 5 C or above 25 Before the device is placed into storage it is recommended that it be cleaned with a damp cloth The device must never be cleaned with flowing water 8 2 Maintenance intervals Daily maintenance includes gt By the dust extractor s user Visual inspection e for damage to the device or its parts e for mechanical damage to the power cable e for filter leaks dust trails or deposits on the air outlets Maintenance must be performed according to accident prevention regulations The device must be disconnected from the power supply 8 3 T
8. oving the device to another site and before cleaning maintenance or replacement or removal of movable parts the device must be unplugged From its first use the device contains toxic dust Maintenance processes and filter replacement must be performed by expert personnel who are wearing appropriate protective gear The device must not be operated without the complete filtration system According to work equipment user directives 89 655 EWG 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 device must be disconnected from the power supply immediately Turn the device off with the main switch and pull the plug If there is a fire the fire department is to be alerted immediately and the fire must be contained by appropriate means Airbox 5 gt Safety instructions ESTA When installing the exhaust arm absolutely all installation conditions must be adhered to Follow all laws guidelines and standards applicable to the application or planned purpose ESTA exhaust arms are for complete flexible capture of smoke and dust Precise suction at the dust or smoke source is the ideal prerequisite for a powerful exhaust system According to EU guideline 98 37 EG the exhaust arms are designated as components Parts are designated as components if they are necessary for safe operation of the device and
9. protection systems but do not themselves serve an autonomous function Preventing mechanical hazards All movable machine parts driven by electric motors as well as all other dangerous machine parts must be covered by fixed securely fastened protective covers that can be removed only with tools Residual risk If a covering that can only be unfastened with a tool is removed there is risk of injury if the machine is running Preventing electrical hazards All electrical parts must be covered by fixed securely fastened protective covers that can be removed only with tools The device complies with Protection Class according to EN 60 335 2 Residual risk If a covering that can only be unfastened with a tool is removed a hazard is posed by electric current Airbox 99300 52 00 ESTA 4 99300 52 00 Intended use a Preventing dust hazards When replacing the filter it is possible to inhale dust Following the instructions in the Cleaning section will minimize this hazard Intended use The AIRBOX has been manufactured according to the state of the art and in compliance with safety regulations The AIRBOX is suitable for exhausting welding fumes where non alloyed steels are welded at portable work locations The purified air can be directed back into the work area The devices are equipped with a filter for dust class M moderate hazard for separation of dust and smoke with an exposure limit gt 0 1 mg m
10. r and the bottom fasteners have been removed installation can begin The device must be transported only with its exhaust arm fully attached Upon delivery please inspect the device for transportation damage Damage determined must be reported and documented immediately ESTA customer service 49 0 7307 804 0 When moving the device make sure the ground can support it and be driven over 7 2 Installation The only installation work necessary is installing the exhaust arm and connecting the current Install the exhaust arm to the AIRBOX in the following steps 1 Lock the castors 2 Place the exhaust arm into the opening and tighten the screws 3 When transporting the AIRBOX make sure that the exhaust arm is in a fully attached position Tilting hazard Airbox 9 Maintenance ESTA 7 3 Start up Only persons authorized under General safety instructions must turn the device on and off Before setting up the cable connection between the device and the power grid check to make sure the operating voltage shown on the model plate is the same as that of the grid The device must be placed on a level surface as near as possible to the workplace Lock the device s wheels Before the device is used its operation must be tested for damage to the device or its parts for mechanical damage to the power cable Start the AIRBOX with the main switch on the front Maintenance and troubleshooting 8 1 Ma
11. remove the filters and dispose of them in compliance with local regulations Pack the device in a suitable manner and dispose of it in compliance with local regulations Due to contamination of the device with toxic dust ESTA cannot take the device back Airbox 99300 52 00 ESTA Device diagram 11 Device diagram AIRBOX 360 rotatable exhaust arm Exhaust hood Filter cassette and fibreglass mat Filter cover Main switch With the model information request the replacement parts you need from V the ESTA replacement part service 49 0 7307 804 831 99300 52 00 Airbox 15 Declaration of conformity ESTA 12 Declaration of conformity Name of manufacturer ESTA Apparatebau GmbH amp Co KG Address of manufacturer Gotenstra e 2 6 89250 Senden Here we explain that the design of the machine Machine Dust extractor for collection transport and elimination of dry dusts and welding fumes Series Welding fume filter Model Airbox conforms to the following regulations 2006 42 EG EC Machine Directive 2004 108 EG EC Directive on Electromagnetic Compatibility Reconciled norms used EN 12100 Safety of machinery basic concepts general propositions part 1 and part 2 EN 13857 oafety of machinery devices and systems safety distances to prevent hazard zones from being reached EN 349 oafety of machinery minimum distances for preventing body parts from being crushed EN 60335 oafety of elect
12. rical appliances for household and similar use part 1 and part 2 69 EN 61000 6 3 Electromagnetic compatibility Emitted interference in residential areas commercial and business operations as well as small enterprises EN 61000 6 4 Electromagnetic compatibility Emitted interference for the industrial sector EN 61000 3 Electromagnetic compatibility Part 11 Limit values Limiting voltage changes National norms and technical specifications used VDI 3677 Filtering separators Senden 30 December 2009 Dr Peter Kulitz CEO 16 Airbox 99300 52 00 ESTA Notes Notes NH ESTA Apparatebau GmbH amp Co KG zm GotenstraBe 2 6 89250 Senden Ay Tel 49 0 7307 804 0 Fax 49 0 7307 804 500 E mail info esta com WWW esta com 99300 52 00 Airbox Notes Notes ESTA Apparatebau GmbH amp Co KG GotenstraBe 2 6 89250 Senden Ay Tel 49 0 7307 804 0 Fax 49 0 7307 804 500 E mail info esta com WWW esta com Airbox ESTA 99300 52 00 ESTA Notes Notes NH ESTA Apparatebau GmbH amp Co KG zm GotenstraBe 2 6 89250 Senden Ay Tel 49 0 7307 804 0 Fax 49 0 7307 804 500 E mail info esta com www esta com 55300 52 00 Airbox 20 Notes Notes ESTA Apparatebau GmbH amp Co KG GotenstraBe 2 6 89250 Senden Ay Tel 49 0 7307 804 0 Fax 49 0 7307 804 500 E mail info esta com WWW esta com Airbox ESTA 99300 52 00
13. roubleshooting Use the following chart if a malfunction is evident Call the ESTA maintenance service right away If there is a malfunction that is not discussed in these lists Do not perform any repairs on the device yourself if they are not explicitly specified Problem Possible cause Possible solution ouction too weak Filter dirty Filter replacement see point 9 Cleaning If dust escapes or clouds up from the air outlets if smoke develops or the fan runs loud the device must be disconnected from the power immediately During maintenance the device must generally be disconnected from the electrical grid ESTA maintenance service 49 0 7307 804 832 ESTA replacement part service 49 0 7307 804 831 Airbox 11 Cleaning filter replacement ESTA Cleaning filter replacement Cleaning work or filter changes must be performed in a well ventilated room or outdoors The people assigned to this work must be instructed on the aspirated toxic materials and wear a breathing protection mask with a class P3 particle filter as well as protective gloves All distractions by uninvolved persons must be prevented O During cleaning work or filter replacement all soiled objects that can no longer be adequately cleaned must be disposed of Such objects must be disposed of in an impermeable bag in compliance with applicable regulations for disposal of such refuse When the housing is open the AIRBOX must not be turned on
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