Supra-Crossflow FFBW Installation and Operation Manual
KNOW YOUR EQUIPMENT READ THIS MANUAL FIRST. Your DUST-HOG system should provide many years of trouble-free service. This manual will help you understand its operation, tell you how to obtain top performance, and show you how to maintain your DUST-HOG unit. Finally, for quick future reference, fill in the system and filter information in the spaces below. Should you need assistance, call the DUST-HOG factory service number shown below. Make certain you have the information below before calling. UAS ORDER #: UNIT MODEL #: UNIT SERIAL #: CARTRIDGE FILTER PART #: SYSTEM ACCESSORIES: INSTALLATION DATE: DUST-HOG CUSTOMER SERVICE 1-800-252-HOGS
TABLE OF CONTENTS Page 1. IMPORTANT NOTICE... 1 1.1 General Cautions... 1 2. INTRODUCTION... 1 2.1 Unit Nomenclature... 1 2.2 Description and Operation... 1 2.3 Air Filtering Operation... 1 2.4 Filter Cleaning Cycle... 1 3. SPECIFICATION TABLE... 4 4. INSTALLATION... 4 4.1 Off Loading and Inspection... 4 4.2 Installation Planning... 4 4.3 Connecting the Modules... 4 4.4 Blower Assembly... 6 4.5 Booth Assembly... 7 4.6 Magnehelic Gage Installation... 8 4.7 Photohelic Gage Installation... 8 4.8 Supra-View Panel Installation... 8 4.9 Supra-I.Q. Diagnostic Panel Installation... 8 4.10 Final Connections for all Gauge Options... 8 4.11 Electrical Installation... 8 5. OPERATION... 9 5.1 Start-Up... 18 5.2 Check List... 18 5.3 Checking the Pulse Cleaning System with your Controller... 18 5.4 Operating Adjustments... 18 6. SERVICE... 19 6.1 Cartridge Filter Removal and Replacement... 20 6.2 Servicing the Direct Drive Motor and Fan Wheel... 20 7. TROUBLESHOOTING GUIDE... 21 8. ILLUSTRATED PARTS... 23 FFBW-DC Parts List... 24 Warranty...Back Cover i
1. IMPORTANT NOTICE This manual contains important safety information and precautionary measures. Read this manual thoroughly and comply with the instructions given. It is impossible to list all potential hazards associated with every dust collection system in each applications. Proper use of the equipment must be discussed with United Air Specialists, Inc. (UAS) or your local DUST-HOG representative. Operating personnel must be aware of, and adhere to, the most stringent safety procedures. 1.1 GENERAL CAUTIONS ON USING DUST CONTROL EQUIPMENT 1. Avoid mixing combustible materials such as aluminum, paper, wood or other organic dusts with dusts generated from grinding metals. A fire hazard could develop from sparks entering the dust collector. 2. When collecting emissions from spark producing processes, care must be taken to reduce any potential fire hazards. System design should include methods to prevent sparks from entering the dust collector. Dust collectors do not contain fire extinguishing equipment. 3. Do not allow any machine operator to put lit cigarettes or any burning object into the dust collector. 2. INTRODUCTION Thank you for selecting DUST-HOG dust collection equipment to assist you in your commitment to a clean and safe environment. We trust that in purchasing our product you have recognized our commitment to continually offer dust collection equipment engineered to each dust collection need and manufactured to the highest standards. 2.1 UNIT NOMENCLATURE EXAMPLE: FFBW-4-EXT FFBW DUST-HOG Supra-Crossflow Vertical Cartridge Module 4 DC Single Module U Single Module, no Motor/Blower 2 2 Modules, with Booth Enclosure 3 3 Modules, with Booth Enclosure 4 4 Modules, with Booth Enclosure EXT Denotes twelve (12) filters per module. No designation denotes six (6) filters per module. 2.2 DESCRIPTION AND OPERATION Supra-Crossflow cartridge units are used for the collection of airborne dust and particulate. The Supra- Crossflow cartridge system provides continuous-duty air cleaning in the work environment or as part of your manufacturing process. As you review this manual, refer to Figure 1 for assistance in locating unit parts. 2.3 AIR FILTERING OPERATION During the air filtering operation, contaminated air enters the Supra-Crossflow dust collector through the door louvers. The downward airflow created by the inlet louvers allows heavier particles to fall into the dust storage drawer. The contaminated air then passes through the cartridge filters. The filter media strips the dust from the airstream allowing only clean air to pass through the filter. The air then passes into the clean air plenum, through the fan enclosure and is discharged from the unit. Refer to Figure 2. 2.4 FILTER CLEANING CYCLE During normal operation, the surface of the cartridge filters becomes loaded with contaminants. The reverse pulse cleaning mechanism provides brief bursts of compressed air, directed through cleaning nozzles, into the interior of the cartridge filters. This pulsing action dislodges the collected particulate from the media where it falls into the dust storage drawer. Refer to Figure 2. United Air Specialists, Inc. 1
Figure 1. 2 United Air Specialists, Inc.
Figure 2. Air Filter Operation & Cleaning United Air Specialists, Inc. 3
During the cleaning cycle, two cartridge filters are cleaned at a time. The solid-state sequential timer actuates a solenoid valve which allows an air diaphragm valve to open for approximately 100 milliseconds. High pressure air from the air manifold reservoir is directed through the cleaning nozzles to the cartridge centers. The quick blast of compressed air induces additional air from the clean air plenum which combine to produce a shock wave, dislodging the dust from the filters being cleaned. The dislodged dust removed from the filters falls into the dust storage drawers. The remaining filters are cleaned sequentially. The sequencing is factory preset at 10- second intervals and is adjustable to adapt to your particular cleaning needs. 3. SPECIFICATION TABLE FFBW Model No. No. of Filter Area Booth 4. INSTALLATION Modules Cartridges (Sq. Ft.) Dimensions FFBW-DC 1 6 1,560 FFBW-DC-EXT 1 12 2,271 FFBW-2 2 12 3,120 8'W x 7'6"H x 7'6"D FFBW-2-EXT 2 24 5,424 8'W x 7'6"H x 7'6"D FFBW-3 3 18 4,680 12'W x 7'6"H x 7'6"D FFBW-3-EXT 3 36 8,136 12'W x 7'6"H x 7'6"D FFBW-4 4 24 6,240 16'W x 7'6"H x 7'6"D FFBW-4-EXT 4 48 10,848 16'W x 7'6"H x 7'6"D 4.1 OFF LOADING AND INSPECTION UAS recommends using a forklift during unloading, assembly and installation of the dust collector and FFBW booth. A crane can be used for the individual modules. Lifting lugs have been provided for each module.! CAUTION For lifting slings, use spreader bars and clevises, not hooks. Do not lift the unit from any point other than the lifting lugs. Connect the lifting sling to both cabinet lifting lugs to distribute the load equality. Upon receipt of your unit, check for any shipping damage. A damaged carton indicates that the equipment may have received rough handling during shipping that may have caused internal damage. Notify your delivery carrier and enter a claim if any damage is found. 4.2 INSTALLATION PLANNING! CAUTION dust collectors are not designed as explosion proof and/or spark resistant units. Do not locate dust collector near dust source in cases where the dust is explosive or a fire hazard. For best installation and operation results, the Supra- Crossflow booth should be installed on a flat concrete foundation inside the factory. If the surface is not flat, modules and booth walls must be shimmed to align bolt holes. When calculating for the foundation, the weight of the dust collector, material collected, Supra-Crossflow FFBW filter booth and all auxiliary equipment must be considered together for seismic loads. Refer to individual specification drawing for Supra-Crossflow FFBW weight. Choose the collector module location with consideration for access to the dust collector, access to the dust storage drawers located inside each module, creation of the shortest run for electrical and air connections, and ease of maintenance. If hazardous dust is involved, consult local authorities for the best location for the unit. 4.3 CONNECTING THE MODULES Each module is identical and can be installed on either end or center interchangeably. The booth assembly builds upon the modules, therefore, it is important to locate the modules on a flat surface. Refer to Figure 3 for assistance with booth assembly. 4 United Air Specialists, Inc.
Figure 3. Typical Module/Booth Installation United Air Specialists, Inc. 5
1. Position one of the modules as an end unit with the louver door side facing the inside of the booth. 2. Install air hose assembly into the air manifold end that will be adjacent to the next module. Use Teflon tape to seal the threads. 3. Move the next module into place so the air hose assembly can be inserted into the manifold. As the air hose assembly is threaded in, move the second module toward the first module. When the air hose assembly is tight (compressed), the two modules should be adjacent. 4. Align the trim strip with the holes in the modules and secure with 1/4-20 x 5/8" self-tapping screws. Do not tighten the screws at this time. 5. Place the third and any additional modules into position following the same procedure for installing air hose assembly and trim strip (steps 1-4). 4.4 BLOWER ASSEMBLY When a Supra-Crossflow unit is purchased, the blower is shipped separately. The blower package contains the motor, motor mounting plate, legs and fan wheel. The blower must mount over a pre-cut exhaust outlet opening on top of the cabinet. Use the hardware provided and mount the inlet cone as shown in the installation drawing (refer to Figure 4). Important: Do not rest the blower assembly on the fan wheel. If the unit has a chamber silencer, refer to Figure 4 for correct placement on top of the Supra-Crossflow FFBW cabinet. Use tek screws to secure the chamber silencer in place. If the unit has safety afterfilters, refer to Figure 5 for correct placement of filters on top of the FFBW dust collector cabinet. Figure 4. Chamber Silencer Installation 6 United Air Specialists, Inc.
4.5 BOOTH ASSEMBLY SNAP-LOCK WALL AND ROOF PANELS Booth wall and roof panels are different widths. Refer to installation drawing provided with unit to identify proper sizes and locations. 1. Bolt the outside of the vertical corner channel on each FFBW dust collector module with 1/4-20 x 5/8" self-tapping screws. 2. Secure the near horizontal roof support channel(s) across the top surface of the modules with 1/4-20 x 5/8" self-tapping screws. 3. Starting at a corner, lay wall base channel in place, squared to the unit and against the vertical corner channel. Sections of the base channel should fit tightly together. Secure with drive nails on 18" centers. Make certain the drive nails are on the base channel centerline (positioned so the drive nails will not be under the edge of the panel). If anchor bolts are used, locate 5/16" anchor bolts on 18" centers with 3/8" bolt projection above the surface. 4. Insert wall panels into the base channel (with the perforated metal side toward the booth inside) to form the first corner. 5. Insert next panel into base channel with tongue end mating with groove end on previous panel (refer to Figure 6). Panels are pushed together to allow snaplock. Acoustical caulking placed on the tongue selflocking recess will exude as panels lock together. 6. As each wall panel is installed, secure the base channel to each wall side panel with #10 sheet metal screws. NOTE: No screws are needed in snap-lock panel joints. 7. Review the roof plan shown on the installation drawing provided with the unit and locate roof panels and front horizontal channel. Place roof panels in position, one at a time, and lock together in same method as side panels. TRIM 1. Mount outside trim pieces in place using #10 sheet metal screws. 2. After all outside trim has been installed, install inside trim at wall-to-roof corners. Anchor the inside trim at all tongue and groove panel joints and at all internal panel stiffeners. Tighten all screws. COMPRESSED AIR CONNECTION! CAUTION Shut off and slowly release the pressure in the compressed air piping and/or the Supra-Crossflow compressed air reservoir manifold prior to servicing this equipment. 1. Remove the plastic plug from the Supra-Crossflow air manifold prior to making the final compressed air pipe connection. Install air supply pipe components on the end of the module. Use Teflon tape to seal the threads. 2. Check nylon tubing between solenoid and diaphragm valves to make sure the fittings hold the tubing firmly in place. 3. Ensure that 1" NPT plug is tightened in the manifold of the opposite end module and use Teflon tape to seal.! CAUTION Do not allow water and/or oil from the compressed air system into the compressed air manifold on the unit. To ensure a water-free air supply, a water filter with automatic drain or a condensation trap with automatic drain must be installed just before the piping enters the Supra-Crossflow unit. Clean, dry, 90-110 PSIG compressed air is required for the pulse cleaning system to properly function. Compressed air consumption is approximately nine (9) scfm per module. A shut off valve, pressure regulator and pressure gauge should be installed close to the unit. United Air Specialists, Inc. recommends dedicated oil and water removal filters be used to ensure clean, dry air is delivered to the pulse system. Contact your local DUST-HOG representative for information on the United Air Specialists, Inc. pneumatic valve kit. Refer to Figure 1 for compressed air piping connection. NOTE: A 1" diameter or larger compressed air supply pipe is required. Provide 1" minimum compressed air line piping to the unit. The pipe diameter should be based on the number of modules, main line pressure, length of pipe run and number of pipe bends from the main line to the unit. The pipe connection for the Supra-Crossflow unit is located on the side of the air reservoir manifold on the front of the unit, as shown in Figure 1. The connection size is a female 1" NPT fitting. United Air Specialists, Inc. 7
NOTE: Purge the compressed air line to remove any debris prior to making the final connection to the compressed air manifold. CURTAINS AND AIR SUPPLY 1. Secure filter booth curtain bracket assembly in place on the top panel with 1/4-20 x 3/4" self-tapping screws. Tighten all screws. 2. Install acoustical curtains on the curtain bracket. Start by installing the curtain marked #R-1 on the right side of the booth. Secure in place with 3/8" plastic cap nuts. Join the Velcro edges together. LIGHTS 1. Bolt the fluorescent light roof brackets through the booth roof and wall panels in four places with 5/16-18 x 2 1/2" bolts, lock washers and nuts. Make certain the bolt head faces the installer. 2. Bolt the fluorescent light fixture to the fluorescent light roof bracket in two places with 3/8-16 x 3/4" bolts and lock washers with bolt heads inside fixture. 3. For booths wider than two modules, flat lights are provided. Bolt to roof panel in center of module with 3/8-16 x 3/4" bolts and lock washers with bolt heads inside the fixture. NOTE: Light bulbs are not furnished with the fixture. 4.6 MAGNEHELIC GAGE INSTALLATION If your system was ordered with a Magnehelic Gage, remove it and the hardware from the box. Instructions for mounting and connecting the Magnehelic Gage are provided from the manufacturer. Follow the instructions using the hardware provided. It should be installed within sight of the unit as shown in Figure 3. NOTE: The hardware provided is designed for surface mounting of the Magnehelic Gage. Make certain to install the 1/8" NPT pipe plugs in the pressure ports on the back of the gauge. Install the tube fittings in the pressure ports on the side of the gauge. Mount it to the bracket and the bracket to a support structure. 4.7 PHOTOHELIC GAGE INSTALLATION If your system was ordered with a Photohelic Gage, remove it and the hardware from the box. Instructions for mounting and connecting the Photohelic Gage are provided from the manufacturer. Following the instructions using the hardware and UAS mounting bracket provided. The Photohelic Gage and mounting bracket should be installed within sight of the unit as shown in Figure 3. Hardware to mount the bracket to the support structure is not supplied by UAS. NOTE: Make certain to install the two (2) jumper wires (not supplied by UAS) as shown in the instruction manual provided with the gauge. Refer to Figure 9. 4.8 SUPRA-VIEW PANEL INSTALLATION Mount the Supra-View control panel within sight of the unit, isolated from vibration. Do not mount it on the Supra-Crossflow dust collector or the Supra-Crossflow FFBW filter booth. Hardware to mount panel is not supplied by UAS. For electrical connections, refer to the wiring diagram located inside the Supra-View enclosure. Make all wiring connections from the electrical service to the fan motor starter(s), fan motor(s), Supra-View control panel and solenoid valves according to the drawings supplied. Refer to the Supra-View Installation and Operation Manual for proper installation details. 4.9 SUPRA-I.Q. DIAGNOSTIC PANEL INSTALLATION If your system was ordered with a Supra-I.Q. diagnostic panel, please refer to the Supra-I.Q. Installation and Operation for proper installation details. 4.10 FINAL CONNECTIONS FOR ALL GAUGE OPTIONS For any control system, connect the black plastic pressure tubing (25 feet provided by UAS) to the gauge or panel fittings and the Supra-Crossflow. Connect the clean air plenum on the modules to the low pressure port on the gauge or panel. Zero, calibrate and maintain the gauge as recommended by the manufacturer on the instructions provided with the gauge. If a Supra-I.Q. panel is used, connect the dirty air plenum on the Supra-Crossflow FFBW to the high pressure port on the gauge or panel. Refer to Figures 7 and 8. 4.11 ELECTRICAL INSTALLATION! CAUTION All electrical work should be performed by a qualified electrician in accordance with local electrical codes. Disconnect electrical power before installing or servicing any electrical component. 8 United Air Specialists, Inc.
GENERAL Several types of standard electrical components can be installed to control and monitor your Supra-Crossflow system, ensuring proper cleaning of the cartridge filters. A fan motor starter(s) is required to start and stop the system. The motor starter circuit should consist of a properly-sized, main fused disconnect or circuit breaker, short circuit protective device(s), contactor(s) and overload relay(s) for protection of the blower(s). A 115/1/ 60 low voltage (2 amp) control circuit is required for the pulse cleaning controls. Any one of the following control configurations can be used (refer to Figures 9-11 for wiring schematics): Motor starter(s) with Supra-Clean timerboard for continuous pulse (Magnehelic Gage). Refer to Figure 9 for recommended wiring. Motor starter(s) with Supra-Clean timerboard for setpoint pulse (Photohelic Gages). Refer to Figure 9 for recommended wiring. Motor starter with Supra-View Panel for self contained differential pressure display, pulse control and alarm. Refer to Figure 10 for recommended wiring. Motor starter with Supra-I.Q. Diagnostics Panel for complete monitoring and automated pulse control. Refer to Figure 11 for recommended wiring. Refer to UAS sales order to verify the number of motor branch circuits (number of modules) and the pulse control configuration purchased with your unit. MOUNTING OF THE CONTROLS Mount the motor starter(s) for the fan motor control(s) in a convenient location. The motor starter(s) is provided by others, unless specifically ordered from United Air Specialists, Inc. Mounting hardware is not supplied by UAS. Mount the solid-state cleaning controls (Supra-Clean, Supra-View or Supra-I.Q.) in a convenient location. It is recommended that the controls be mounted on a wall or pedestal in a convenient area subject to minimal vibration and electrical noise.! CAUTION Avoid mounting the Supra-Clean, Supra-View and Supra-I.Q. Panel on the collector due to vibration generated from blower assembly and the pulsing system. PULSE CLEANING CONTROLS For a more in-depth explanation of the cleaning control features and options, refer to Section 5 or the Installation and Operation Manual supplied with the Supra-Clean timerboard, Supra-View Panel or Supra- I.Q. Diagnostics Panel. ELECTRICAL CONNECTIONS FOR BOOTH LIGHTS Follow local codes for wiring lights in parallel. Light wiring and on/off switch are not provided by UAS. Mount the on/off switch in a convenient location. SOLENOID VALVE ENCLOSURE WIRING The solenoid valves at the Supra-Crossflow must be wired correctly to the pulse controls. Refer to Figure 12 when making connections from the pulse controls (Supra-Clean timerboard, Supra-View or Supra-I.Q. Diagnostics Panel) to the solenoid valve enclosure(s). Example: Figure 12 shows the FFBW-2 having six valve locations. This means when the system pulses, 1 is the first pulse in the sequence, 2 is the second, 3 is the third, etc. Unless specified on the UAS sales order, the customer will supply interconnecting material (conduit, wiring, etc.) from the pulse controls to the dust collector. 5. OPERATION! CAUTION Never operate the dust collector without the blower compartment bolt-on panel installed.! CAUTION Prior to unit start-up, all installation set-up instructions must be completed as specified by this manual, Supra-Clean Installation and Operation Manual, Supra-View Installation and Operation Manual, Supra-I.Q. Installation and Operation Manual, as well as any manuals supplied by other equipment manufacturers, as they apply to your dust collector. United Air Specialists, Inc. 9
Figure 5. Safety Afterfilter Installation 10 United Air Specialists, Inc.
Figure 6. Booth Panel Interlock Connection United Air Specialists, Inc. 11
Figure 7. Pressure Gage Installation Diagram 44-10219-0001 12 United Air Specialists, Inc.
Figure 8. Supra-I.Q. Diagnostic Panel Installation Diagram United Air Specialists, Inc. 13
Figure 9. Power & Elementary for Units with Photohelic & Magnehelic Gage 44-10214-0001 04-2555-01, REV C 14 United Air Specialists, Inc.
Figure 10. Power & Elementary for Units with Supra-View Panel 44-10215-0001 04-2589-01 United Air Specialists, Inc. 15
Figure 11. Power & Elementary for Units with Supra-I.Q. Diagnostics Panel 44-10216-0001 04-2559-01, REV A 16 United Air Specialists, Inc.
44-10217-0001 04-2555-01, REV C Figure 12. Solenoid Wiring to Pulse Controls United Air Specialists, Inc. 17
5.1 START-UP 1. Inspect the installation area and make certain no tools, parts, etc. have been left anywhere on or inside the Supra-Crossflow unit. Check each fan discharge to make certain it is free from all debris. 2. Open the louver doors and check the cranks on the filter elements for tightness. If they are loose, handtighten only. 3. Turn on the blower(s). On initial start-up, make certain the fan rotation is correct. A rotation arrow is located on the fan wheel. All fan wheels rotate in a clockwise rotation as viewed from the drive end. NOTE: Proper blower rotation is required to move the designed amount of air. A blower rotating in the incorrect direction will only move about 40% of design airflow. Turn on the compressed air supply to the unit. Adjust the pressure regulator until the gauge reads 90-110 PSIG (6.2-7.7 BAR). 5.2 CHECKLIST Check the exhaust. Exhausting air should remain visibly clean. If a leak develops, it will be first noticed after cleaning pulsation as a puff of dust. Check the pressure differential reading on the pressure measurement device (Magnehelic, Photohelic, Supra- View Panel, Supra-I.Q. Diagnostics Panel). NOTE: If your system is controlled by the Supra-I.Q. Diagnostics Panel, the yellow airflow alert light may be illuminated. This is normal until the Airflow Calibration routine has been performed at the Supra-I.Q. Diagnostics Panel. This must be performed during start-up of your collection system once all of the inlet(s) and ductwork is in place. Refer to the Supra-I.Q. Installation and Operation Manual and perform the Code 4 Airflow Settings steps. second intervals and deliver a crisp sounding pulse to each filter. The valves should not deliver a weak or lingering pulse. To check the pulse sequence for proper firing, perform the following: If your system is supplied with a Supra-Clean timerboard (with Magnehelic or Photohelic Gage) or Supra-View Panel, place the Continuous Clean/PS switch on the timerboard to the Continuous Clean position. The MOT AUX terminals at the timerboard must have continuity for the pulsing to become active. This can be done by disconnecting the motor wiring from the motor starter and energizing the motor starter to close the isolated auxiliary contact wired to the timerboard MOT AUX terminals. Verify robust and consistent pulse firing of each valve. If your system is supplied with a Supra-I.Q. Diagnostics Panel, place the system in Continuous Clean by entering Code 5 and at the SET MODE state enter 1 for continuous cleaning. Terminals 1 and 2 at terminal strip P7 must have continuity for the cleaning system to activate. This can be done by placing a temporary jumper across 1 and 2 to activate the cleaning sequence. Please allow 45 seconds after panel power-up for pulsing to start as the Supra-I.Q. cleaning mode(s) operate on a delay. Verify robust and consistent pulse firing of each valve. When test is complete, enter code 5 and at the SET MODE state enter 2 for Auto-tune cleaning mode. 5.4 OPERATING ADJUSTMENTS Please confirm the type of pulse cleaning controller delivered with your system. Your system was delivered with one of the following: Magnehelic Gage with Supra-Clean timerboard Photohelic Gage with Supra-Clean timerboard Supra-View Pulse Panel Supra-I.Q. Diagnostics Panel 5.3 CHECKING THE PULSE CLEANING SYSTEM WITH YOUR CONTROLLER Check the cleaning system for proper operation. The compressed air pressure should be between 90-110 PSIG (6.2-7.6 BAR). The Supra-Clean, Supra-View and Supra-I.Q. panels are factory set to pulse every 10 seconds. Refer to the Supra-Clean, Supra-View or Supra-I.Q. Installation and Operation Manual to change these initial settings. Check to ensure the pulse (diaphragm) valves are firing at approximately 10- NOTE: It is important that the compressed air pressure in the manifold(s) is above 90 PSIG immediately prior to a pulse. If the delivery capability of your compressed air source cannot return the manifold pressure to above 90 PSIG during the Pulse Delay (time between pulses) interval, adjust the pulse delay at the timerboard or Supra-I.Q. and monitor the pressure drop. A longer interval will raise the operating differential pressure and a shorter interval will lower the operating differential 18 United Air Specialists, Inc.
pressure. Allow sufficient time for the system to stabilize after each adjustment before further adjustment is made. Adjust until the desired pressure differential is reached. MAGNEHELIC GAGE WITH SUPRA-CLEAN TIMERBOARD When using a Magnehelic Gage with Supra-Clean pulse timerboard, the timerboard is always set to Continuous Clean pulse mode. If the filters are operating at a higher or lower differential pressure than desired, adjusting the pulse frequency (Pulse Delay) can often modify the steady-state pressure differential. The factory setting is 10-second intervals. Adjust the Pulse Delay on the Supra-Clean timerboard and monitor the pressure drop on the Magnehelic Gage. A longer interval will raise the operating differential pressure and a shorter interval will lower the operating differential pressure. Allow sufficient time for the system to stabilize after each adjustment before further adjustment is made. Adjust until the desired pressure differential is reached. PHOTOHELIC GAGE WITH SUPRA-CLEAN TIMERBOARD When using a Photohelic Gage with Supra-Clean pulse timerboard, the timerboard can be set to PS pulse mode (pulse cleaning activated by the Photohelic Gage) or Continuous Clean pulse mode to override the Photohelic Gage. With the Photohelic Gage, the desired pressure differential can be maintained by adjusting the high and low setpoints on the gauge. Adjust the upper setpoint to the desired differential pressure setting plus 0.25" (factory recommended setting is 3"). Adjust the lower setpoint to the desired setting minus 0.25" (factory recommended setting is 2.5"). This allows a 0.5" deadband and the pulse system will maintain the desired differential pressure (factory recommended operating point is 2.75"). If the differential pressure remains above the desired operating point, the pulse frequency can be increased (shorter Pulse Delay ). The high and low needle setpoints on the Photohelic Gage can be adjusted as the filters season and continuous pulsing occurs. Adjust both needles upward in 0.5" increments until pulsing stops. Continue adjustments, when required, until the high setpoint reached 6". No further adjustments should be made above 6" w.g. SUPRA-VIEW PULSE PANEL When using the Supra-View panel the pulsing controls can be set to PS pulse mode ( On-Demand cleaning similar to Photohelic control) or Continuous Clean pulse cleaning. The Supra-View comes standard with a cartridge differential measurement/display, pulse time United Air Specialists, Inc. sequence controls and a customer usable high cartridge pressure alarm contact all in one enclosed assembly. The high, low and alarm setpoints are adjusted by opening the enclosure door and adjusting the appropriate selector switches for desired control. Adjustments to the setpoints can only be done with the door open. Refer to the Supra-View Installation and Operation Manual for adjustment details or refer to the Supra-View enclosure door for operating instructions. SUPRA-I.Q. DIAGNOSTIC PANEL The Supra-I.Q. Diagnostics Panel can be set to operate similar in Continuous Clean, Setpoint Clean (similar to Photohelic control) or Auto-tune clean mode. Auto-tune mode is designed to conserve compressed air usage while maintaining lowest possible cartridge differential pressure. Auto-tune allows the minimal amount of compressed air usage while maximizing filter life. In Auto-tune mode, the controller will automatically adjust the filter differential pressure to obtain the most costeffective setting. Refer to the Supra-I.Q. Installation and Operation Manual for a complete listing of operating parameters and adjustment instructions. ALL CONTROL OPTIONS As the cartridge filters become loaded with dust, the differential pressure across the filters will increase. This will result in a loss of air volume. Should the dust collection capture effectiveness be reduced, open the flow control damper to return the system to increase to original design air volume. 6. SERVICE BEFORE SERVICING, NOTE THE FOLLOWING: 1. Disconnect all electrical power to the unit and control panel. 2. Shut off and slowly bleed the compressed air supply from the manifold. 3. Collected dust may be hazardous. Consult proper authorities for handling and disposal. 4. Collected dust may be a potential fire hazard. Grinding or operations involving open flames should not be performed without fire protection measures in place. Refer to Section 1 for additional precautions. 5. Wear appropriate protective clothing when servicing the dust collector. 6. Disposal of collected dust must be according to state and local environmental regulations. 19
NOTE: Do not allow the dust drawer to overfill. This can cause poor collector performance and require extensive cleanup if the dust overflows when the drawer is removed. 6.1 CARTRIDGE FILTER REMOVAL AND REPLACEMENT Supra-Series cartridge filters are the only replacement filters that will provide the high level of performance expected from the dust collector. Replacement cartridge filters should be ordered when the differential pressure across the filter is consistently above 4"-5" w.g. or system airflow is inadequate. To order filters, call 1-800-252-4647. To replace the filter(s): 1. Disconnect all electrical power. 6.2 SERVICING THE DIRECT DRIVE MOTOR AND FAN WHEEL Periodically inspect the fan blades to ensure proper fan life. Grease the motor every 2,000 hours with high grade ball and roller bearing grease. The recommended grease is Chevron SRI#2. Periodically inspect the fan wheel coupling mounting bolts for tightness. Re-tighten as necessary to ensure the fan wheel does not loosen and come in contact with and rub the inlet bell. Clearance between fan wheel and inlet bell should be kept at flush ± 0.125". Magnehelic and Photohelic are registered trademarks of Dwyer Instruments, Inc. Teflon is a registered trademark of E.I. DuPont de Nemours & Co. 2. Remove the louvered doors by releasing the T- handle latches and rubber door latches. Swing open or lift off door and then place the louver assembly out of the way.! CAUTION The filter may be heavy due to the weight of the collected dust. 3. Remove the filter and crank assembly from the FFBW dust collector and place them on a plastic sheet to prevent dust contamination. 4. Disassemble the crank rods from the filter elements and install the crank rods in the new filter elements. Always replace the outside crank gasket when replacing filter elements. 5. Back off the square nut until it touches the lock nut on the end of the crank rod. 6. Hang the filter and crank assembly on the hanger bracket nearest the rear. 7. Turn the crank clockwise until the element bottoms out and stops. Make certain the filter element clears the bracket collar. If any misalignment occurs or if the filter is hung up on the collar, a dust leak will result. 20 United Air Specialists, Inc.
7. TROUBLESHOOTING GUIDE Use the troubleshooting guide to correct any problems that occur with your dust collection unit. If the problem or condition continues, contact UAS customer service at 1-800-252-4647. PROBLEM POSSIBLE CAUSES POSSIBLE SOLUTIONS Fan motor won t start or won t stay Input circuit not operational. Check input to motor circuits for running. proper voltage on all legs. Improper electrical wiring. Starter overloads tripped. Check and correct internal motor wiring for proper connections based on the incoming line voltage. Wiring diagram is found on lead access plate. Check for proper motor starter overload rating against full load amps on the motor nameplate. Adjust or replace overloads as required. Dust emissions from clean air Filters installed properly. Inspect and reinstall cartridge discharge. filters. Filters damaged. Replace the damaged filter(s) with new Supra-Series filters. Insufficient airflow. Fan rotation is backwards. If the fan is not rotating in the correct direction, reverse the rotation. Air inlet(s) obstructed. Filters plugged. Inspect and clean all louver doors Refer to troubleshooting procedures for continual pressure drop. Continual, excessive pressure Compressed air supply problems. Check incoming compressed air for drop (over 6") on filter monitor proper pressure (90-110 PSIG) and gauge. flow (1.5 cubic feet per pulse). Correct any problems. Pulse cleaning system not Check incoming 110v power to pulse timerboard. Check for blown fuse on timerboard. Replace if necessary. Check for 110v output from timerboard. If incoming voltage is correct and fuse is not blown, replace timerboard. Photohelic Gage not adjusted properly. Reduce high setpoint on Photohelic Gage to 3". Reduce low setpoint on Photohelic Gage to 2 1 /2". United Air Specialists, Inc. 21
7. TROUBLESHOOTING GUIDE (CONTINUED) PROBLEM POSSIBLE CAUSES POSSIBLE SOLUTIONS Continual, excessive pressure Pulse system not adjusted Check for proper pulse valve drop (over 6") on filter monitor properly. operation. Replace damaged parts as required. Pulse settings incorrect. Adjust pulse on time to 0.10 second. Adjust pulse off time to 10 seconds. Dust storage area is full. Filters are at the end of their useful life. Empty dust drawers. Replace filters. Order replacement Supra-Series filters from United Air Specialists, Inc. by the part number found on the filters or as listed in the front cover of this manual. 22 United Air Specialists, Inc.
8. ILLUSTRATED PARTS Exploded View United Air Specialists, Inc. 23
FFBW-DC Parts List Item No. Part No. Description Quantity 1 33-xxxx DC Cartridge Filter (View sticker on unit or on end of filter for part number) 6 1A 33-xxxx EXT Cartridge Filter (View sticker on unit or on end of filter for part number) 12 2 02-6083-01/02 Access Door Assembly FFBW with Gasket 1 2A Call Factory Access Door Assembly FFBW Spark Trap with Gasket (01 Left/02 Right) 1 2B 42-0176 Gasket, Inside, Filter Access 16 ft. 2C 39-0265 Access Door Retaining Latch 2 3 10-8258 Panel, Inspection, Rear 1 3A 42-0163 Gasket, Neoprene Sponge/per door 8 ft. 4 18-1138 Filter Crank Handle DC 6 4A 18-1329 Filter Crank Handle DC-EXT 6 4B 30-0657 Filter Locating Nut 6 4C 30-0653 Lock Nut 6 5 18-1135 Air Manifold Weldment 1 6 07-0128-02 Diaphragm Valve 1" 3 6A 07-0116 Diaphragm Repair Kit, 1" BUNA-N 1 7 20-1624-050 Solenoid Valve Enclosure 1 7A 07-0133 Solenoid Valve Repair Kit 1 7B 20-1631 Replacement Solenoid Valve, 1 /8" 3 8 39-0202 5" Flexible Latch 2 8A 39-0204 Latch Keeper 2 9 02-6087 Silencer Housing Assembly 1 9A 10-8112 Silencer Rear Access Panel 1 9B 02-6516 Silencer/Safety Filter Assembly 1 9C 33-0307 Safety Filter 2 9D 33-1273 Safety Filter Retaining Springs 8 10 20-xxxx 5 HP Motor Call UAS 1 10A 18-1129 Motor Mounting Frame 1 10B 32-0228 Fan Wheel Steel 1 10C 32-0249 Fan Wheel Aluminum 1 10D 32-0229 Cone 1 11 03-1384 Back Draft Kit Louver Door (Not Shown) 1 12 18-1599-01 Dust Drawer, Right 1 12A 18-1599-02 Dust Drawer, Left 1 13 38-0814 Fitting BS, Tube, Male, 90 degrees 6 14 38-0780 Tubing Polyethylene, 1 /4" O.D. x.040" Wall 3 ft. 15 38-0781 1 /4" Tubing Bulkhead Connector 1 15A 38-0808 Brass Coupling, 1/4" 1 15B 38-0827 Sintered Metal Dust Filter 1 16 02-6061 Manifold Airline Assembly 1 17 10-7381 Module Trim Strip 1 18 30-0532 Tech Screw, 1 /4" x 1" long 20 19 20-1603 3 Station Timerboard 1 20 07-0135-08 0-8" Magnehelic Gage 1 21 07-0075 0-8" Photohelic Gage 1 22 38-0780 1 /4" Gauge Tubing 25 ft. 23 18-1635 Light Mounting Bracket 1 24 20-1636 Light 1 25 Call UAS 1 26 45-1367 Booth Curtain Panel, 46" x 48" (End Modules) 1 26A 45-1368 Booth Curtain Panel, 48" x 48" (Center Modules) 1 26B 45-1369 Velcro Connector 5" wide x 48" 1 24 United Air Specialists, Inc.
UNITED AIR SPECIALISTS, INC. LIMITED WARRANTY UAS warrants all equipment manufactured and sold by UAS against defective parts and workmanship for one year from date of shipment to Purchaser, except that commercial or non-industrial air cleaners (other than engineered systems) are warranted for three years from such date. This warranty is subject to the limitations in UAS standard terms and conditions provided to Purchaser. Any unauthorized repairs or modifications or abnormal use or misuse of equipment will void all warranties. In no case will UAS responsibility or warranty extend to equipment not manufactured by UAS. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER WRITTEN, ORAL OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANT- ABILITY, FITNESS FOR A PARTICULAR PURPOSE OR NONINFRINGEMENT. As Purchasers exclusive remedy for any defects in the equipment, UAS will exchange or repair any defective parts during the warranty period, provided such parts are returned, prepaid, to UAS factory. The obligation of UAS is limited to furnishing replacement parts F.O.B. UAS factory or making repairs at UAS factory of any parts which are determined, upon inspection by UAS, to be defective. UAS is not responsible for labor or transportation charges for the removal, reshipment or reinstallation of the parts. IN NO EVENT WILL UAS BE RESPONSIBLE FOR ANY SPECIAL OR CONSEQUENTIAL DAMAGES. To Order Genuine Supra-Crossflow Replacement Parts and Supra-Series Replacement Filters, Call 1-800-252-4647 4440 Creek Road Cincinnati, Ohio 45242 National: (800) 252-4647 Telephone: (513) 891-0400 Fax: (513) 891-4171 http://www.uasinc.com 1997, 2000 United Air Specialists, Inc. Part No. 44-1197 10/00 United Air Specialists, Inc. reserves the right to change design or specifications without notice.