Table of Contents
Summary of Contents for ENVIROSYSTEMS AIRWALL MD
- Page 1 AIRWALL® DUST COLLECTION SYSTEM INSTALLATION, OPERATION, MAINTENANCE AND REPLACEMENT PARTS MANUAL PUBLICATION NO. UM-AW-0211 Copyright 2011 ENVIROSYSTEMS, LLC 2555 N Coyote Dr. Suite 118 Tucson, AZ 85745 (520) 573-3064 (800) 999-0501...
- Page 2 Envirosystems Manufacturing, LLC, 2555 N. Coyote Dr., Suite 118, Tucson, Arizona 85745. TRADEMARK ACKNOWLEDGMENTS Envirosystems Manufacturing, LLC acknowledges the following companies and their trademarks that are used in this manual.
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Page 3: Table Of Contents
TABLE OF CONTENTS TRADEMARK ACKNOWLEDGEMENTS TABLES OF CONTENTS. . LIST OF ILLUSTRATIONS/TABLES SAFETY SUMMARY SAFETY PRECAUTIONS . GENERAL SAFETY INSTRUCTIONS AND CONSIDERATIONS PERSONAL SAFETY WORK AREA SAFETY LIFTING AND CARRYING SAFETY SETUP AND OPERATION SAFETY MAINTENANCE SAFETY . DESCRIPTION AND SPECIFICATIONS INTRODUCTION SYSTEM DESCRIPTION . - Page 4 ELECTRICAL CONNECTIONS TIMER CONTROL BOARD COMPRESSED AIR CONNECTION INSTALLING LIGHTING FIXTURES 2-11 SEALING CCB BEAMS AND SUPPORTS 2-12 ELECTRICAL SCHEMATIC 2-13 OPERATION OPERATION PROCEDURE FILTER CLEANING OPERATION. INTEGRATED CONTROL PANEL DUST COLLECTION DRAWERS . MOISTURE ACCUMULATION CHANGING FILTER CARTRIDGES DUST COLLECTION DRAWERS . FAN MOTOR LUBRICATION TROUBLESHOOTING REPLACEMENT PARTS...
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Page 5: Safety Precautions
SAFETY PRECAUTIONS These safety precautions have been prepared to assist the operator in practicing good shop safety procedures. These safety precautions are to be used as a guide and supplement to all other safety precautions and warnings in: all other manuals pertaining to machines, controls and auxiliary equipment. - Page 6 Observe and follow safety instructions such as NO SMOKING, HIGH VOLTAGE and DANGER in your working area. Accidents can occur that result in serious injury to you or others due to clothing and other articles becoming entangled or in contact with revolving parts, levers and electrical equipment.
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Page 7: Work Area Safety
Know and use the signals for safely directing a crane operator. See WARNING next page. If in doubt as to the size or type of lifting equipment, method or procedure for lifting, contact Envirosystems Manufacturing, LLC before proceeding to lift the equipment or its components. -
Page 8: Setup And Operation Safety
___________________________________________________________ WARNING Never place any part of your body under a suspended load or move a suspended load over any part of another person's body. Before lifting, be certain that you have a safe location for depositing the load. Never work on a component while it is hanging from a crane or other lifting mechanism. -
Page 9: Maintenance Safety
Envirosystems Manufacturing, LLC representative, do NOT work with electrical power "ON". If such statement or advice exists, working with electrical power "ON" should be performed by an Envirosystems Manufacturing, LLC representative. The user must determine that any other person performing work with electrical power "ON"... - Page 10 If such statement or advice exists, working with electrical power "ON" should be performed by an Envirosystems Manufacturing, LLC representative. The user must determine that any other person performing work with electrical power "ON" is trained and technically qualified. Failure to follow this precaution may result in severe bodily injury or death.
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Page 11: Introduction
INTRODUCTION The AirWall dust scrubber is a stand-alone unit that may be installed in an existing location or as part of a new piece of equipment. Capacities range from 10,000 to 30,000 cfm per unit for standard modules. Custom configurations can provide filtration capacities over 100,000 CFM. -
Page 12: Filter Cleaning
FILTER CLEANING Filter cleaning is accomplished by actuating a short burst of air that blows back-ward from the clean side of the cartridge. This dislodges the caked dust that then drops into collection drawers or optional dust collection hoppers. Each pulse cleans two to six filter cartridges, depending on scrubber type, leaving the remaining cartridges available to continue filtering the ventilation air. - Page 13 A optional manual on/off switch is also available and, when installed, allows the pulse system to be activated at any time, whether or not the fan is running. This allows periodic deep cleaning of the filter cartridges and will extend filter life. This option should be monitored when used to prevent accumulated dust being forced backward down the dirty air inlet and out into the workspace.
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Page 14: Airwall Product Specifications
AIRWALL SPECIFICATIONS Model AWC 2S Unit Dimensions Height (Excludes Blower Height) Inch (mm) (1676) Width Inch (mm) (1448) Length Inch (mm) (5283) - Page 15 Filter cartridges (Standard) Spunbond 80/20 Total Filter Area Sq. Ft. 2400 6000 Air Requirements Pulse Air Supply: 3.0 CFM @ 90 – 100 psi (6,2 – 6,9 bars) Electrical Requirements Pulse System: 2A@ 120 VAC, 1-Phase, 60 Hz...
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Page 16: General Information
Besides a common set of hand tools, a forklift or chain-fall will be required to position the fan and motor on top of the AirWall unit clean-air plenum. NOTE: Envirosystems Manufacturing, LLC (ES) must rely on the skill and expertise of its customers and the customer’s installation... - Page 17 Apply a bead of sealant around the fan inlet opening on top of the cleaning plenum. Use a forklift or chain-fall to lift the exhaust fan and motor assembly into position on top of the filter cartridge section clean-air plenum. See CAUTION.
- Page 18 Position the fan exhaust pointing off any one of the four sides. If the exhaust is to be pointed off the side of the AirWall unit, the front and rear clearance will change depending on which side the exhaust is pointed. Align the mounting holes in the fan/motor assembly with the mounting holes in the top plate of the clean-air plenum.
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Page 19: Electrical Connections
Apply sealant, or a closed-cell foam gasket material, to the flange attachment surface on the inlet side of the safety filter assembly. Attach the transition duct, using the duct flange doublers provided. Move the filter assembly, together with any required transition ducting up to the rear of the AirWall unit. -
Page 20: Filter Cleaning Systems
The electrical requirements for the Photohelic gage and switch are 120 VAC, single phase, 60 Hz. Only a qualified electrician should make the connection of this device. FILTER CLEANING SYSTEMS With the standard filter cleaning system, the reverse pulse is released from the diaphragm valve by the solenoid pilot valve, which is activated in turn by the timer control board. -
Page 21: Integrated Control Panel
timer control board to energize the solenoids inside the AirWall unit clean- air plenum, which in turn opens the diaphragm valves and pulses the filter cartridges. Connect the positive (hot) lead from 120 VAC to L1 on the Photohelic control card. Connect the common lead (white) from 120 VAC to L2 on the Photohelic control card. -
Page 22: Installing Filter Cartridges
airborne dust and the set points used for determining the cleaning cycle. Typical air consumption will be approximately 1.8 CFM per AirWall unit. Use the following procedure to complete the compressed air connection. Although the AirWall unit is designed for a 1 in. NPT supply line, the supply line may be smaller than 1 in. - Page 23 Beginning with the back row, gently lift the filter cartridge and position the hooked end of the support rod in the hole in the spider assembly welded in the opening of the tube sheet. The short, right-angle bend in the support rod will keep the support rod from turning completely around when it is positioned in the spider assembly.
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Page 24: Initial Start Up Procedure
INITIAL START UP PROCEDURE ___________________________________________________________ WARNING Wear clean, approved eye or face protection while performing the initial start up procedure. Failure to follow this instruction may result in serious personal injury. ___________________________________________________________ Checking Fan Rotation Use the following procedure to check the fan rotation. With the elec turning on the AirWall unit. - Page 25 carefully turn the small adjusting screw located on the front of the gage face. Turn the screw slowly one way or the other to achieve a zero reading. With the fan on, check the Photohelic gage and note the needle indica-tion.
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Page 26: Filter Cleaning Operation
The AirWall LD models have 3 blow-pipes, while the AirWall MD and HD models have 5 blow-pipes. The air pulse will cause a shock wave to blow backward through the filter cartridge. This dislodges the accumulated dust, which falls into dust collection drawers at the bottom of the AirWall unit. -
Page 27: Integrated Control Panel
knobs located on the front of the Photohelic gage or the keypad on the digital sensor module. Adjustments can be made as required to accommodate various process variables and to maintain the filters at their optimum efficiency. Integrated Control Panel (ICP). An optional NEMA 12 ICP is available with controls for starting up to four (4) AirWall unit’s along with their on-demand filter cleaning controls. -
Page 28: Dust Collection Drawers
The fan motor controls consist of a RUN indicator light and a START/STOP selector switch. Turning the selector switch clockwise to the START position and holding it until the ON indicator light illuminates will start one or more (up to four) AirWall units. -
Page 29: Moisture Accumulation
MOISTURE ACCUMULATION At the start/end of each shift, press the MOISTURE DRAIN pushbutton to allow any water to escape from the pulse accumulator tank. The MOISTURE DRAIN pushbutton is located on the left front of the AirWall unit. CHANGING FILTER CARTRIDGES ___________________________________________________________ WARNING When changing filter cartridges, always wear OSHA-NIOSH approved... -
Page 30: Fan Motor Lubrication
emptying the dust collection drawers. Failure to follow this instruction may cause serious personal injury. ________________________________________________________ FAN MOTOR LUBRICATION The most common cause of premature bearing failure is improper lubrication. The fan motor provided with AirWall dust collection systems will be one of two types. One type has sealed-for-life bearings and requires no maintenance. - Page 31 An electrical AC hum caused by a defective starting relay. Obstruction in high velocity air stream can cause rattle or pure tone whistle. An air flow noise or hollow whistle type of noise from the clean air plenum when the compressed air line is opened is an indication of a loose or leaking vent line or fitting between a diaphragm valve and its pilot solenoid.
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Page 32: Ordering Replacement Parts
ORDERING REPLACEMENT PARTS To order replacements parts for your AirWall unit, write to: Envirosystems Manufacturing, LLC. 3202 E. President St. Tucson, AZ 85714 USA Phone: 1-800/999-0501 or 520/573-3064 Fax: 520/573-3068 E-Mail: envirosystems@att.net Web: www.envirosystemsllc.com Be sure to include, or have access to, the following:... - Page 33 The following replacement parts are common to AirWall Models AW60-MD, AW80-MD and AW100-MD. QUANTITY PART DESCRIPTION PART NUMBER Baffle, (section) galvanized 14-11-001 Strip, corner 14-10-019 The following replacement parts are common to AirWall Models AW100-HD, AW120- HD and AW160-HD. QUANTITY PART DESCRIPTION PART NUMBER Baffle, (section) galvanized 14-11-004...
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