BFS-12-8-10-H-CVS-ownersmanual1376560382736.pdf

FROM CLEAN AIR CONSULTANTS, INC.

BENCHTRON

MODEL BFS-12-8-10-H-CVS-SC

DOWNDRAFT /BACKDRAFT

WORKSTATION

OWNER’S MANUAL

CUSTOMER: CORPUS CHRISTI ARMY DEPOT

INTRODUCTION

Congratulations!! You have chosen equipment made in America.

This manual contains precautionary statements relating to worker safety, and should be read in its entirety before you uncrate or attempt any installation of this product. A fire protection expert should be obtained in the event the product is intended for uses which present a potential risk of fire or fire propagation. Refer to the appropriate authorities.

Manual Accuracy Contact Info

We have made every effort to be exact with the instructions, specifications, and drawings. However, sometimes errors do occur and we apologize for them.

Owing to our policy of continuous improvement, as well as the custom design of our units, your equipment may not exactly match the manual. If you find this to be the case, and you need additional help, please do not hesitate to call for technical support.

Before calling, find the serial number on the nameplate (see below). This will allow us to provide the answers to your questions.

Serial number and Model number

If you have any service questions, parts requests, or general questions about the equipment, please call or write us at the location listed below.

Clean Air Consultants, Inc.

2525 National Drive Garland, TX 75041

Toll free: 800-289-0189 Phone: 972-278-2664

Fax: 972-278-1810 E-mail: info@filter-1.com

If you have any comments regarding this manual, please write us at the address above, or e-mail us at info@filter-1.com.

Visit our website at www.filter-1.com

KEEP THIS LITERATURE IN A SAFE PLACE FOR FUTURE REFERENCE.

mailto:info@filter-1.com mailto:info@filter-1.com http://www.filter-1.com/

GENERAL INFORMATION ABOUT YOUR UNIT

CAC Job# 22008

Model: BFS-12-8-10-H-CVS-SC Serial Number: SEE PAGE 5

Distributor: CLEAN AIR CONSULTANTS

NOTES:

Date Purchased: Date Installed:

Record Start-Up Data Here:

Motor Voltage: (Measured): Motor Current (Measured)

Motor Voltage (From Nameplate):

To order spare parts contact your local distributor or:

Clean Air Consultants / Filter-1 2525 National Drive Garland, TX 75041 Toll Free: 800-289-0189

FAX: 972-278-1810

Unit model number, serial number, and part description is required.

Table of Contents

INTRODUCTION

GENERAL INFORMATION ABOUT YOUR UNIT

SERIAL NUMBERS

IMPORTANT INFORMATION

To The Installer Transportation Damage

SAFETY PRECAUTIONS

SAFETY WARNINGS

A WORD OF CAUTION

Determination of Electrical Service Requirements Addendum

BFS / BFD SPECIFICATIONS

AVAILABLE OPTIONS

Regain Air (If Included) Reduced Flow Cleaning (If included) Off Line Cleaning (If included) HEPA Safety Afterfilter (If included) Carbon or Odor Control Afterfilters (If included) Mechanically Actuated Lift Table (If included) High Temperature Cutoff (If included) Spark Trap (If included) Fire Sprinkler Couplings (If included) Sound Control (If included)

OPERATING THE BENCHTRON

Assembly Air Filtration Operation Filter Element Purge Cycle

START-UP

CHECKLIST

COMPRESSED AIR

ADJUSTMENTS

Timer Setting Cleaning Time Interval

PARTS

MAINTENANCE

Compressed Air Cartridge Removal and Installation for Some BFS Units

BFS / BFD CARTRIDGE REMOVAL

BFS / BFD CARTRIDGE INSTALLATION

PREVENTIVE MAINTENANCE CHECKLIST

TROUBLESHOOTING

INTERMATIC 24-HOUR TIMER INSTRUCTIONS

ELECTRICAL SCHEMATIC 1

ELECTRICAL SCHEMATIC 2

SUBMITTAL DRAWING PAGE 1

SUBMITTAL DRAWING PAGE 2

PARTS LIST

MSDS

Paint

RESPONSIBILITY STATEMENT

LIMITED WARRANTY

SERIAL NUMBERS

UNIT SERIAL NUMBER

UNIT 1 12-38-750

UNIT 2 12-38-751

UNIT 3 12-38-752

UNIT 4 12-38-753

UNIT 5 12-38-754

UNIT 6 12-38-755

UNIT 7 12-38-756

UNIT 8 12-38-757

UNIT 9 12-38-758

IMPORTANT INFORMATION

To The Installer

Before installing this unit, you should read this manual thoroughly to become familiar with specific items which must be adhered to, including but not limited to, unit voltage, amperage, and ventilation considerations.

Transportation Damage

All units are securely packed in shipping containers designed to meet International Safe

Transit Association specifications. The unit must be checked upon arrival for external damage. If damage is found, a request for inspection by carrier’s agent must be made in writing immediately.

The unit must be carefully inspected on arrival for damage and bolts or screws which may have come loose in transit. In the event of damage the consignee should:

1. Make a notation on delivery receipt of any visible damage to shipment or container.

2. Notify carrier promptly and request an inspection.

3. With concealed damage, carrier must be notified as soon as possible—preferably within five days.

4. File the claim with the following support documents within a nine month statute of limitations.

a. Original or certified copy of the Bill of Lading, or indemnity bond

b. Original paid freight bill or indemnity in lieu thereof.

c. Original or certified copy of the invoice, showing trade and other discounts or reductions.

The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from dealers for transportation damage.

SAFETY PRECAUTIONS

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION

ATTENTION INSTALLING PROFESSIONAL

As a professional installer, you have the obligation to know the product better than the customer. This includes all safety precautions and related items.

Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to safety warnings. Often during installation or repair, it is possible to place yourself in a position which is more hazardous than when the unit is in operation.

Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a customer in its safe use.

Safety is a matter of common sense…a matter of thinking before acting. Most dealers have a list of specific good safety practices…follow them.

The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if there is a direct conflict between existing practices and the content of this manual, the precautions listed here take precedence.

WARNING

If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance

Installation and service must be performed by a qualified installer or service agency.

SAFETY WARNINGS

Follow all electrical and safety codes, as well as the National Electrical Code (NEC), National

Fire Prevention Agency (NFPA), and the Occupational Safety and Health Act (OSHA).

It is necessary for all electrical work to be performed by a qualified electrician according to the most stringent applicable codes. Be sure starter, conduit, and wiring for blower motor is of the proper size. Disconnect, lock out and tag out prior to beginning any electrical service.

The unit has been prewired to the voltage specification on the purchase order. Please verify before engaging power.

WARNING: Permanent damage to the motor will be sustained if connected to voltages other than the normal operating voltage for which the unit has been pre-wired.

NFPA standards require specific duct design and dust collector configuration when collecting potentially reactive metal dusts such as aluminum, magnesium, titanium, and other materials.

A giudeline for determining the precautions to be taken can be found in NFPA 497. Other

NFPA standards may be specific to your application. Consult current NFPA standards for applicable safeguards which may be required for the installation, operation, and service of this product.

Current NFPA standards are available from:

NFPA

1 Batterymarch Park

Quincy, MA, 02269

800-344-3555.

Note: NFPA™ is a registered trademark of National Fire Prevention Agency

Additional references are the Uniform Building Code and Uniform Mechanical Code.

A WORD OF CAUTION

Owning and operating FILTER-1 machines involves certain known hazards. With knowledge and training these hazards can be minimized. Our engineers are available to guide you if necessary.

EXPLOSION HAZARD Venting may be required in some applications. Outside location of some equipment may be required. Consult competent advisers in this regard.

FIRE HAZARD No sparks should be allowed to enter the machine without a properly installed fire suppression system.

Personnel should never allow smoking material to enter these machines.

The volatile organic compounds that are collected with this machine are very dangerous if they become too concentrated.

FILTER-1 units operate on voltages of 110 to 460 AC volts. All service personnel should be aware of this fact and should have adequate training before any repairs are attempted on the equipment. All repairs are to conform to NEC electrical standards.

ROTATING MACHINERY The fan inside this unit is rotating at 1740-3600 rpm. The electrical source should be locked out and the unit allowed to come to a full stop before any entry is made to the fan compartment.

COLLECTED MATERIAL: It is possible that the dust being collected in this unit is considered hazardous or toxic, therefore proper personnel safety and waste disposal practices should be followed. Contact your plant safety coordinator for direction.

Always disconnect the unit from the power source before working on or near the motor or wiring assemblies. Lock out and tag out disconnects to prevent the unexpected application of power.

Using your hand to test the running temperature of a motor can be a very painful experience

Normal body temperature: 98.6F

Threshold of pain caused by heat: 120.0F

Average temperature of hot water tap: 140.0F

Average temperature of hot coffee: 180.0F

Normal operating temperature of a

Fully loaded electrical motor, open type

70 degrees ambient temperature: 174.0F

You cannot wash your hands in 140.0 degree water!!

You cannot stir a fresh cup of coffee with your finger!!

You cannot place your hand on a motor that is operating properly without burning your hand!!

Determination of Electrical Service Requirements Addendum

Determination of electrical service requirements for Clean Air Consultant/Filter-1 equipment requires strict adherence to National Electrical Code. While many electricians are familiar with the classic application of the National Electrical Codes, the unique nature of this equipment requires an in-depth application of said codes. While this section will not attempt to repeat the applicable codes, it will discuss the larger considerations to hopefully prevent under sizing the electrical service for Clean Air Consultant/Filter-1 equipment.

Begin your design by compartmentalizing your thinking.

1. Design the feed from the primary breaker box to the unit location.

Priority is conductor protection

Voltage delivery is important

Do not try to bring motor protection all the way back to breaker box. Design from the breaker box to the unit. Think robust electrical delivery

2. Design Service Disconnect at unit

Motor protection – Factory or Field

Additional motor protection for system components

Prudent to order motor protection from the factory

This equipment is primarily a large horsepower motor that is directly attached to a matching blower implement. The rotating speed of this combination ranges from 1750 to 3600 RPMs.

Additionally, the control box of this equipment may control additional motors for augers, pumps or conveyors that are used to move collected dust to an appropriate location or move water through filtration or agitation.

The following should be considered and each items applicable code considered when designing the service and selecting the wiring gauge.

Large motors with large wheels have high moments of inertia and take longer than normal times to come to speed.

o Large in rushes of current up to 8 times the nameplate voltage can be expected for each motor.

o Equipment driven usage that starts/stops the dust collection equipment with dust producing equipment can cause poorly selected circuit protection to over-heat and have nuisance tripping.

o Underestimated gauge selection will prevent the upsizing of circuit breakers to eliminate this nuisance.

o Slow trip circuit breakers are a must o Multiple motors requires consideration when sizing service

If motor protection is not ordered with Clean Air Consultant/Filter-1 equipment, then protection of the equipment and protection of the conductors must be considered simultaneously.

The factory almost never has a failure related to wiring or motor protection sent from the factory. Almost all field failures are due to poorly, under-designed electrical service delivered to the unit. Failure to take into account all considerations when providing electrical service to

Clean Air Consultant/Filter-1 equipment could result in unexpected expenses incurred by installing contractors. Prudence would suggest erring on the side of over-sizing the service versus designing service to the letter of the code.

BFS / BFD SPECIFICATIONS

See Submittal drawing in this manual for the exact specifications for your equipment

MODEL NUMBER OF CART CART. SQ. FT. DIMENSIONS CFM HP

BFS-3-2-1.5F 2 550 1 TABLE 24 X 32 1,200 1.5

BFS-3-4-3F 4 1100 1 TABLE 30 X 43 3,000 3

BFS-4-3-3 3 825 1 TABLE 38 X 30 3,000 3

BFS-4-3-3-48F 3 825 1 TABLE 48 X48 3,000 3

BFS4-6-3 6 1650 1 TABLE 48 X 30 4,000 3

BFS-4-6-5 6 1650 1 TABLE 60 X 30 5,000 5

BFS-4-6-7.5 6 1650 1 TABLE 60 X 30 5,000 5

BFS-5-4-3F 4 1100 1 TABLE 60X30 4,000 3

BFS-6-4-3F 4 1100 1 TABLE 72 X 30 4,000 3

BFS-7-5-3F 5 1375 1 TABLE 84 X 30 4,000 3

BFS-8-6-5F 6 1650 1 TABLE 96 X 30 5,000 5

BFS-10-7-5F 7 1925 1 TABLE 120 X 30 6,000 7.5

BFS-12-8-7.5 8 2200 1 TABLE 144 X 30 8,000 7.5

BFD-3-4-3F 4 1100 2 TABLES 36X30X2 3,000 3

BFD-4-6-5F 6 1650 2 TABLES 48X30X2 5,000 5

BFD-4-6-5-48F 6 1650 2 TABLES 48X48X2 5,000 5

BFD-5-6-5F 6 1650 2 TABLES 60X30X2 5,000 5

BFD-6-6-5F 6 1650 2 TABLES 72X30X2 5,000 5

BFD-6-8-7.5F 8 2200 2 TABLES 72X30X2 8,000 7.5

BFD-7-8-7.5F 8 2200 2 TABLES 86X36X2 8,000 7.5

BFD-8-8-7.5F 8 2200 2 TABLES 46X80X2 8,000 7.5

BFD-8-10-7.5F 10 2750 2 TABLES 26X30X2 8,000 7.5

BFD-8-10-15F 10 2750 2 TABLES 96X30X2 10,000 15

BFD-10-10-7.5F 10 2750 2 TABLES 120X80X2 8,000 7.5

BFD-10-12-15F 12 3300 2 TABLES 120X30X2 10,000 15

BFD-12-12-15F 12 3300 2 TABLES 144X30X2 10,000 15

*Consult factory for custom dimensions

AVAILABLE OPTIONS: STANDARD:

Powered adjustable table height TEFC motors

Odor control & carbon afterfilters Direct drive, non-overloading fan

Spark trap for welding or heavy grinding Compressed air required 60 PSIG

ASHRAE & HEPA safety afterfilters Cartridge filters

Custom paint colors Automatic 24 hour self clean

Crane Slot Magnehelic gauge

High temperature cutoff Sound control

Pulse clean—reduced suction with variable frequency drive

Regain air system

Variable frequency drive for soft start and energy conservation

Reverse jet pulse compressed air cleaning system

Off line cleaning Gulf Blue industrial acrylic enamel

**Filter-1 has a policy of continuous design improvement and reserves the right to update designs and specifications without notice.

AVAILABLE OPTIONS

Regain Air (If Included)

The regain air system has two adjustments. The overall flow is adjusted by restricting the outlet on the top of the unit’s discharge. The more it is restricted, the more regain you will get. It is recommended that not more than 20% of the air volume be diverted to regain air.

This impacts the performance of the unit. Too much regain super charges the unit, and can actually move dust out of the containment area and into the rest of the plant.

The second adjustment is the direction. The registers in the regain plenum can be used to direct the regain air towards operations that are localized in the unit. For example, if grinding is taking place in the unit, regain air can be focused in that direction to ensure that respirable dust is more effectively moved from the work zone.

Reduced Flow Cleaning (If included)

This unit may be equipped with a variable frequency drive (VFD), which serve two purposes.

1. Soft start feature

a. Saves electricity demand on start up

2. Reduced blower speed

a. Turns the blower back on during cleaning at a slow speed to prevent dust migration during cleaning.

Off Line Cleaning (If included)

This equipment may be furnished with an offline clean feature. This would activate the pulse cleaning system for a variable amount of time—typically 5-15 minutes—every time the blower is turned off.

HEPA Safety Afterfilter (If included)

This unit may be equipped with HEPA safety afterfilters in the blower compartment. A second magnehelic gauge gives the status of the HEPA filters.

Carbon or Odor Control Afterfilters (If included)

This unit may be equipped with odor control afterfilters, which are used to remove gasses or odors. Typically, these are refillable modules containing either activated carbon or potassium permanganate to absorb the odors.

Mechanically Actuated Lift Table (If included)

This equipment may have been supplied with an up/down table that is electro-mechanical in operation. The table moves 8” up and down using the up/down switch.

High Temperature Cutoff (If included)

This equipment may be furnished with a high temperature cutoff. If there is a flame up in the cartridge, caused by material deposited on the cartridge, the high temperature cutoff will interrupt the voltage to the blower. It will reset when cooled down.

Spark Trap (If included)

This option is designed to reduce the chance of live sparks reaching the filters. A spark trap is intended to stop momentum of live sparks by deflection, redirection, and slowing sparks down thus allowing them to cool. Note: Filter-1 uses fire retardant filters which will not propagate a flame, but it is possible to melt a hole in the media. Also, be aware that certain types of dust are flammable.

Fire Sprinkler Couplings (If included)

Filter-1 only installs sprinkler couplings, which is a removable plate with a ½” NPT closed nipple welded through it. This allows the fire suppression technician to easily install sprinkler heads without damaging the filters. All sprinklers should be fitted by an experienced, trained, and certified installer.

Sound Control (If included)

Fiberglass compressed and quilted with a 5 mil white vinyl impregnated fiberglass cloth cover. Flame spread and smoke developed rating of 5ASTM, designation E-84-(70).

OPERATING THE BENCHTRON

Assembly

The bench comes fully assembled. Light bulbs will have to be installed in the light fixture and the cartridges checked for tight fit.

NOTE: Air supply must be oil and moisture free. Purge air lines to remove any debris before connecting to air manifold.

Normal operation consists of the following:

Air Filtration Operation

During the air filtering operation, sanding or grinding is being accomplished in the bench.

Contaminated air is sucked towards the grate and rear slots. Immediately behind the slots are the cartridge filters where the dirty air is pulled onto the outside surface of the cartridges.

The cartridges are made of a Nanofiber substrate and further treated with a UL Class 2 fire retardant chemical that is 99.8% efficient on all particles .5 microns and larger. This material will then capture the dust on the outside surface. The system is provided with an automatic clean system to be activated by the operator.

Filter Element Purge Cycle

This system is provided with a compressed air cleaning system. This cleaning system is activated by a 24-hour timer to be set by the operator, or automatically by an offline cleaning relay. It is set by sliding the white pegs on the dial toward the outside of the dial representing the time at which the collector is to go into clean mode. It is suggested that the 24-hour timer be set for coffee breaks, lunch break, and after shift times. It is preferable for a system to go into self clean when the blower is turned off. However, it is quite capable of cleaning itself, even with the blower turned on. The Magnehelic gauge at start-up will be approximately 1 to1.5". It is anticipated that the operation of the system will be between 1.5" and 2" of static pressure across the cartridge filters, although pressures of up to 3" are not unknown. With the setting of the 24-hour timer by the operator, when the system goes into self clean, it activates the automatic pulse timer.

The automatic timer then begins a sequential operation of pilot valves. The pilot valves open up starting with cartridge 1 (which is Valve 1) on the extreme left side.

A sharp report will be heard of the air being discharged from the header through the diaphragm valve and into the cartridges. This is accomplished by the pilot valve relieving the pressure on the back side of the diaphragm valve. It then sequences in valve 1 through the total number of valves in the system. Then it begins to repeat itself. Generally, from the factory, the delay (off) time between cartridges is approximately ten to twenty seconds. It can be set to as low as five seconds or as long as sixty seconds. The system then sequences to each valve, which in turn blows the dust off each cartridge. Dust is blown down into the hopper below, which has a screw conveyor in the bottom. The screw conveyor moves the dust to the end of the hopper where the vacuum connected to the venturi moves the dust into the duct, then into a 55 gallon drum for disposal without being touched by human hands.

START-UP

1. Turn on air supply to manifold and adjust for 90 to 100 PSI gauge. This is a proper setting for the system. It is a mandatory requirement that dryer and a filter regulator of significant quality be installed immediately in front of the air entering into the compressed air chamber. If moisture and oil are not eliminated from the compressed air system, it is possible that air contaminated by water and oil will be blown into the cartridge, thus blinding the cartridge and necessitating its replacement.

2. The blower can be activated through Switch 2, which is a magnetic motor starter furnished with the unit. Upon initial start-up proper rotation is necessary; looking down through the louvers over the blower determine that the blower is turning in the proper rotation. There will be an arrow marked on the blower and the top of the motor housing. All fan motors are TEFC and, therefore, have their own little fan at the top of the motor. It is quite easy to see this fan, which will give you the rotation of the unit.

3. Inside this system is a tube sheet. In this tube sheet, the cartridges are sealed tightly.

The magnehelic gauge furnished and mounted on the front of the timer box registers the pressure differential between the tube sheet and the inside of the bench. Upon initial start-up, this would be approximately 1" - 1.2". It is anticipated that the system will run no lower than 1.2" and as high as 2.5". A good operational point would be between 1.5" and

3".

4. Also supplied with the system is a 24-hour timer. The timer is operated either manually or in auto mode. It is suggested that the timer be set to self clean at each break, at lunch-time, and at the end of each work shift. This will vary depending on the number of shifts run. It is not anticipated that it would ever be necessary to self clean in excess of 60 minutes at any one time. In fact, a 10-minute cleaning should be sufficient. Whether it is sufficient or not is determined by the operator observing the magnehelic gauge. If the gauge continues to climb to over 2", then it would be necessary to lengthen the cleaning cycle. It may be necessary to add to the number of times it cleans per day. This is left to the discretion of the operator, and can only be determined after approximately two to four weeks of operation. If it self cleans after the shift is over, the operator must be assured that compressed air is available to run the cleaning system. This unit is equipped with

IVEC, which will give a soft start to the blower and also will turn the blower back on at about 10 Hz to keep any random dust in the unit so it doesn’t escape during cleaning.

WARNING

IF FAN COMPARTMENT HAS BEEN OPENED, BE CERTAIN THAT IT IS

CLEAN BEFORE OPERATING, OTHERWISE FLYING OBJECTS WILL

RESULT.

CHECKLIST

1. Check rotation. Looking down through the louvers over the blower determine that the blower is turning in the proper rotation. There will be an arrow marked on the blower and the top of the motor housing. All fan motors are TEFC and, therefore, have their own little fan at the top of the motor. It is quite easy to see this fan, which will give you the rotation of the unit. The large fan is attached to the other end of the shaft.

2. Check exhaust. Be sure a significant amount of air (200 - 400 FPM) is blowing down through the regain louver.

3. Check for air flow. The fan should be checked to be sure the fan does not rub against the cone, and that the isolation system is loose and free to support the motor blower.

4. Check pressure drop. Pressure drop across the tube sheet will be from approximately 1" to 1.5" during start up.

5. Check diaphragm valves and their respective air lines to the pilot valves to assure no air is leaking from the pilot valve system, thus allowing the diaphragm valve to stay open. This will be observed by listening. If the diaphragm valves are open, it will be heard as a rush of air when compressed air is put into the system. The pilot valve is made to hold the diaphragm valve in place. The pilot valve is spring loaded to stay shut unless 120 volts is applied to the solenoid coils. Any leakage of air from the back of the diaphragm valve to the pilot valve and through it will allow the air from the back of the diaphragm valve to escape. The diaphragm valve will then stay open and air will be escaping from the compressed air chamber and will not allow the system to build up the pressure for the self-cleaning purposes. If a leak is found, it must be corrected.

As a further check of the cleaning system, please open the timer box and, after setting for the proper operation, as discussed earlier, press the switch to close the contacts, thus putting the system into manual cleaning. At this time you will hear diaphragm Valve 1 release air. This is a rush of air and can be confirmed by placing a finger over the outlet jet. A sudden rush of air will be heard and the diaphragm valve will then fire. A sudden report will be heard as the diaphragm valve dumps the air from the compressed air chamber through the cartridges.

About 10 to 20 seconds later, depending on the setting of the timer, the same thing will be accomplished with diaphragm Valve 2 and will continue down the line from left to right.

As each valve fires, the operator should place a finger over the outlet port of the pilot valve to assure that the air has been released and that the pilot valve is thus relieving the diaphragm valve when the air is being pressured through the cartridge to blow off the dust. After it reaches the last station, the system will automatically cycle itself back to the first station. If any pilot valve is not releasing the air and thus relieving the diaphragm valve, determination should first be made that power is being applied to the coil. At this time the diaphragm valve operating the suction venturi will turn on and the conveyor will start to rotate.

**COMPRESSED AIR SHOULD BE 90 TO 100 PSI**

COMPRESSED AIR

The compressed air will be hooked up to the compressed air header. It is necessary that a regulator, aglomerator, and air cleaner be installed in the air line to ensure that the air is clean, dry, and free of oil and moisture, from the time it enters the header. Moisture and oil in the compressed air system can clog up the inside of the cartridges, forcing them to be replaced early, instead of on their regular time schedule.

ADJUSTMENTS

Timer Setting

Compressed air is to be regulated at a pressure of 90 to 100 PSI. The timer, located in the sealed NEMA 1 box, has been set at the factory for 10 to 20 seconds delay between cleaning cycles. In looking at the timer board, you will see two adjustments; on time and off time. The off time is the time between cleaning cycles. The on time is the time the power is applied to the pilot valve. That time frame is very small, and setting should be left as it is sent from the factory. The setting between cycles, which is the off time, has been set at the factory between 10 and 20 seconds. The adjustment there is to determine that the compressed air system will allow the pressure tank to be completely repressurized after a dump. In most systems, this can be accomplished in 10 seconds or less. If, for some reason, there is a restriction in the compressed air flow, then the timing cycle must be adjusted to assure that the compressed air tank is completely refilled with air before the next cleaning cycle is activated. The timer, located to the right of the automatic pulse timer board, is adjustable and should be set for a minimum of cleaning twice per day, once at lunch and once at the end of a shift. If a second shift is present, we suggest setting for the second shift lunch period and again at the end of second shift. If the system begins to build up pressure, more tabs can be moved to have the system cleaned during breaks as well. The initial Magnehelic gauge should read about 1.2". As it proceeds to 2.5", the system needs to be cleaned more often.

Any increase in the on time does not do anything but waste compressed air. The very short cycle is all that's necessary.

Cleaning Time Interval

The cleaning time interval is preset at the factory between 10 and 30 seconds and factory settings should be maintained. The timer determines the initiation of the cleaning cycle. It is suggested that the time be set to clean at lunch for a minimum of 10 minutes and after the shift is over for a minimum of 10 minutes. This adjustment is made in the timer lugs themselves inside the timer box.

PARTS

Dust Collector Section

The dust collector assembly consists of the following:

Cartridge holding system

Blow down system

Louvers

Blower

Controls for the automatic cleaning

The walls and frame are attached to the dust collector assembly plus the regain air plenum on the top. The dust collector consists of a 10 HP blower, attached to a TEFC motor. There are eight (8) cartridges in the design through which the air is pulled. The parts numbers are shown in the attached parts list.

Pilot and Diaphragm Valve Assembly

Occasionally the diaphragm valve kit will need to be replaced. The frequency of replacement is expected to be one or two every 2 -3 years. The pilot valve also has a kit which contains a coil.

Louver

The louver set in output air duct directing the regain air in the booth and is adjustable to control air flow.

Automatic Cleaning System

The automatic cleaning system is on a timer and 24-hour timer. The 24-hour timer has an 8 event set point, which can be adjusted for the cleaning time of day, as necessary. The timer is to have 120V applied to it all the time, and the clock should be set to the right time of day.

Frame and Hopper

The units come completely assembled, but it is necessary to check the fit of the filters after shipment. This is done by removing the cover plate on the back side of the unit and checking the cartridge for fit and rotation to be sure they are sealed. To remove the cartridges, it is necessary to remove the end plate.

MAINTENANCE

Before any servicing:

Disconnect all power to unit by deactivating the fused disconnect. Lock out and tag out the unit.

Shut down and bleed compressed air from the air supply.

MAGNEHELIC READINGS CONSISTANTLY ABOVE 4”

REQUIRE REPLACEMENT OF THE CARTRIDGES

Compressed Air

It is best to use a water separator that is continuously automatic bleeding. It not, the compressed air system should be checked daily, and the bowl bled down of any water or oil contaminant that has come out of the compressed air system.

Cartridge Removal and Installation for Some BFS Units

Cartridges are removed in the following manner. Some care must be taken to assure the new cartridges are installed with the gaskets properly seated to prevent leakage and that the media is not damaged, in some fashion, by sheet metal pieces in the way:

1. Remove cover plate on the back side of the unit.

2. Turn handle down to release cartridge then turn the cartridge two turns counter clockwise.

3. Move the filter to side to break the gasket seal between the filter and the tube sheet.

The filter should slide out and away from the cabinet, and put into a plastic sack for disposal.

4. Inspect the tube sheet to ensure all gasket sealing is free of dust and ensure proper seal.

5. Install the new cartridges by reversing the above process.

BFS / BFD CARTRIDGE REMOVAL

1. Remove the hopper and table.

2.

2. Remove the screws holding the louver panel in place.

3. Behind the louver panel is a spark trap; remove. The filters will be visible.

4. Turn the cartridge two turns counter-clockwise, then turn handle down to release the cartridge.

5. Move the filter to side to break the gasket seal between the filter and the tube sheet (at the top). The filter should slide out and away from the cabinet; put into a plastic sack for disposal.

6. Inspect the tube sheet to ensure all gasket sealing is free of dust and ensure proper seal.

BFS / BFD CARTRIDGE INSTALLATION

Installation of a cartridge is as follows:

1. Inspect the tube sheet to ensure all gasket sealing is free of dust and ensure proper seal.

2. Place the cartridge support in the horizontal position with the cartridge support plate in a position to rest the cartridge on.

3. Place the support into the impression in the bottom of the cartridge. Rotate cartridge two turns counter-clockwise to lengthen and tighten support.

4. Grasp the handle, and move into a vertical position, while guiding the top of the cartridge into the cartridge guide pins mounted on the tube sheet.

Note: The cartridge clamping is too tight if the pleats of the cartridge begin to waver.

In that case, the bottom plate should be rotated back clockwise 90º.

The cartridge top will move if the cartridge is too loose. The cartridge is too loose if a business card can be slipped between the gasket and the tube sheet. Rotate the cartridge counter-clockwise to tighten.

5. Replace the spark trap.

6. Replace the louver panel.

7. Replace the hopper and table.

PREVENTIVE MAINTENANCE CHECKLIST

PM: Benchtron BFS/BFD

Are these instructions complete and accurate?

[Y] Yes, they are current and valid.

[N] No, they are not current and valid. Reference the edits I have made.

STEP

NO.

WORK DESCRIPTION FREQUENCY

RUNNING CHECKS

CHECK PULSE VALVES FOR FUNCTION. MONTHLY

RECORD EXHAUST (200-400 FPM).___________________ MONTHLY

CHECK BLOWER BEARINGS FOR NOISE AND WEAR. MONTHLY

CHECK BLOWER MOTOR FOR NOISE MONTHLY

CHECK CONTROL PANEL FUNCTIONAL AND SAFETY FEATURES. MONTHLY

CHECK DIAPHRAGM VALVES & AIR LINES FOR AIR LEAKAGE. MONTHLY

PUT SYSTEM INTO MANUAL CLEAN CYCLE TO ENSURE IT IS FUNCTIONING

PROPERLY.

MONTHLY

ALSO ASSURE THE SCREW CONVEYOR IS TURNING AND SUCTION VENTURI

IS OPERATING.

MONTHLY

CHECKS MADE WHILE EQUIPMENT TURNED OFF

CHECK FILTERS FOR CAKING, HOLES AND WEAR. MONTHLY

EMPTY DUST 55 GALLON DRUM AND DISPOSE OF DUST PROPERLY. WEEKLY

INSPECT BULKHEAD FOR DUST ACCUMULATION. MONTHLY

CHECK COMPRESSED AIR SYSTEM. DAILY

TROUBLESHOOTING

SYMPTOM: Pulsing and failure of valves at any location.

CAUSE FIX

Ruptured diaphragm

Pinched or plugged tubing between

Open solenoid coil

Disassemble valve in question and inspect diaphragm(s). Replace if necessary.

Disassemble valve in question and inspect diaphragm and also tubing. Replace if necessary.

Check continuity of solenoid coil with ohmeter.

Replace if necessary.

SYMPTOM: Continuous passage of compressed air through one or more blowpipes.

CAUSE FIX

1/4" OD tubing leaking or broken

Solenoid armature not sealing properly. A steady flow of air from the solenoid exhaust port is felt by placing a finger over the port.

Diaphragm valve air bleed hole or passage restricted.

Inspect and repair as required. Always use new ferrules in fittings when replacing tubing.

Remove valve core from solenoid. Disassemble the valve core. Remove particles of dirt, scale, or rust from the valve body and from around the armature. Check for smooth action and reassemble.

Disassemble and inspect the diaphragm valve.

Check for plugged air bleed hole in diaphragm.

Also check for scale or rust or metal shavings causing diaphragm not to seat properly

CAUTIONS:

Note: Air supply must be oil and moisture free. Purge air lines to remove any debris before connecting to air manifold.

Do not allow any machine operator to put lit cigarettes or any burning object into inlet; may cause possible fires in the dust collector.

INTERMATIC 24-HOUR TIMER INSTRUCTIONS

ELECTRICAL SCHEMATIC 1

JOB NO: 22008

ELECTRICAL SCHEMATIC 2

JOB NO: 22008

SUBMITTAL DRAWING PAGE 1

SUBMITTAL DRAWING PAGE 2

PARTS LIST

MSDS

Paint

RESPONSIBILITY STATEMENT

Filter-1 dust collection products are manufactured, sold and delivered to our end users for a wide variety of dust producing applications by Clean Air Consultants and our distributors. It is the position of Filter-1 that our units do not cause fires or explosions; rather operational conditions caused by the manufacturing process being ventilated does. Herein we wish to list our responsibilities and those of our equipment owners as well.

At Filter-1, we feel it is our responsibility to provide our end users with up to date designs of dust collection equipment specifically designed for the dust producing process requiring ventilation. Filter-1 dust collection products can be provided with many safety options regarding operating conditions caused by upsets in the ventilation and dust collection process. During the proposal process, we must work together with the owner/end user, to enable the collection systems to be provided with the proper safety equipment. We provide a wide array of options specifically designed to be included in the manufacture of dust collection systems where hazards exist or might be caused by the process, operational errors or lack of maintenance.

At Filter-1, we feel it is the responsibility of our customers and end users to provide us with proper system application information to provide the best equipment for the application. We further ask that as system operators you realize that there are many situations that can arise that we, as equipment manufacturers, cannot control and therefore it is your responsibility.

Some of these are duct design, equipment location and specific quantitative representation of general dust loading of our equipment. We also feel it is your responsibility as the owner or end user, to be aware of codes, regulations and standards applicable to your system and that you as owners see these are followed. Therefore, Filter-1 assumes no liability for the fitness of any of its products—with respect to fire and explosions—for a particular installation or application.

This statement of responsibility is to be included with all quotations and proposals generated by CLEAN AIR CONSULTANTS and or its authorized distributors. By accepting any of our quotations you thereby accept our responsibility statement.

LIMITED WARRANTY

Filter-1 warrants to the original purchaser that the major structural components of the goods will be free from defects in materials and workmanship for 10 years from the date of shipment, if properly installed, maintained and operated under normal conditions. Filter-1 warrants all components and accessories including air locks, fans, conveyers, motors, etc., for 12 months from date of shipment. Filter- 1 does not warrant against damages due to corrosion, abrasion, normal wear and tear, product modification, or product misapplication.

After Filter-1 has been given adequate opportunity to remedy any defects in material or workmanship, Filter-1 retains the sole option to accept return of the goods, with freight paid by the purchaser, and to refund the purchase price for the goods after the goods are returned undamaged and in usable condition. Such a refund will be the full extent of Filter-1’s liability. Filter-1 should not be liable for any other costs, expenses or damages whether direct, indirect, special, incidental, consequential or otherwise.

The terms of this warranty may be modified only by a special warranty document signed by Cliff or Frank Watson. Failure to use factory replacement parts including filters may void this warranty.