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Donaldson BOFA AD 500 iQ User Manual

Fume extraction system
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This manual contains specific precautions related to worker safety. The hazard alert image denotes safety
related instructions and warnings in this manual. DO NOT install, operate, or perform maintenance on this
system until you have read and understood the instructions, precautions and warnings contained within this
manual.
English
Original Instructions
AD 500 iQ
Fume Extraction System
User Manual
Installation, Operation, and Service Information
UM-AD 500 iQ-BOFA-US
Revision 4.4

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Summary of Contents for Donaldson BOFA AD 500 iQ

  • Page 1 AD 500 iQ Fume Extraction System User Manual Installation, Operation, and Service Information This manual contains specific precautions related to worker safety. The hazard alert image denotes safety related instructions and warnings in this manual. DO NOT install, operate, or perform maintenance on this system until you have read and understood the instructions, precautions and warnings contained within this manual.
  • Page 2 Donaldson BOFA Donaldson BOFA Technical Service If a problem arises with your system, please refer to the troubleshooting section of this manual. If the problem is still not resolved, please: • Visit our website at for online help. donaldsonbofa.com •...

  • Page 3: Table Of Contents

    AD 500 iQ User Manual Table of Contents Overview �������������������������������������������������������������������������������������������������������������������������������������������� 5 1�1� Front view of AD 500 iQ 1�2� Rear view of AD 500 iQ 1�3� Overview of control panel Safety information ���������������������������������������������������������������������������������������������������������������������������� 8 2�1� Important safety notes 2�2� Warning and information labels 2�3�...
  • Page 4 Donaldson BOFA 6.2.1. 75% filter blocked indication 6.2.2. Pre-filter replacement 6.2.3. Combined filter replacement Intelligent Operating System (iQ) display �������������������������������������������������������������������������������������24 7�1� Visual alarms on the iQ system 7�1�1� Over-temperature alarm 7.1.2. Heat detection shut-off 7�1�3� Hose blocked alarm 7.1.4. Gas filter monitoring - VOC sensor (optional) 7�1�5� Door open alarm (optional) 7�1�6� Run safe feature 7�2�...

  • Page 5: Overview

    AD 500 iQ User Manual Overview 1�1� Front view of AD 500 iQ Control panel Standby button Company branding Up/Enter/Down buttons USB port Key lock door catch Combined filter Combined filter lever Door latches Pre-filter Lockable castors Lever location bracket...

  • Page 6: 1�2� Rear View Of Ad 500 Iq

    Donaldson BOFA 1�2� Rear view of AD 500 iQ Blower cooling Mains on/off inlet switch Blower cooling outlet Compressor connection (optional) Exhaust outlet Signal cable (optional) Mains inlet Air inlet Castors...

  • Page 7: 1�3� Overview Of Control Panel

    AD 500 iQ User Manual 1�3� Overview of control panel The diagram below shows an overview of LCD features. Internal extraction Blower status icon Airflow value in CFM system temperature or m³/h °F/°C Real-time Target airflow combined filter set point condition Real-time pre-filter Blower run hours/...

  • Page 8: Safety Information

    Donaldson BOFA Safety information 2�1� Important safety notes Concerning symbols used on the extraction system and referred to within this manual. Symbol Meaning Refers to an immediately impending danger. If the danger is not avoided, it DANGER could result in death or severe (crippling) injury. Please consult the manual when this symbol is displayed.

  • Page 9: 2�2� Warning And Information Labels

    AD 500 iQ User Manual Dangers to eyes, breathing, and skin Once used, the filters within the extraction system may contain a mixture of particulates, some of which may be sub-micron size. When the used filters are moved, it may agitate some of this particulate, which could get into the breathing zone and eyes of the operative.

  • Page 10: 2�3� Serial Number Label

    Donaldson BOFA 2�3� Serial number label Location: Top right on the right-hand side panel. Meaning: This label contains a variety of information about the extraction system, including: • Company name, address and contact number • Extraction system model • Extraction system serial number •...

  • Page 11: 2�4� Fire Risk Warning

    AD 500 iQ User Manual 2�4� Fire risk warning In the very rare event that a burning ember or spark is drawn into the fume extraction system, it may be possible that the filters will ignite. Whilst any resultant fire would typically be retained within the fume extraction system, the damage to the extraction system could be significant.

  • Page 12: Before Installation

    Donaldson BOFA Before installation 3�1� Packaging removal and system placement Before installation, check the extraction system for damage. All packaging must be removed before the system is connected to the power supply. Please read all instructions in this manual before using this extraction system.
  • Page 13 AD 500 iQ User Manual 4. Check the filters are located in their correct position before closing the door and securing the door latches. Note: The door will not close fully if the combined filter has not been secured in place using the internal lever (as detailed below).

  • Page 14: Installation

    Donaldson BOFA Installation The system has been designed to remove and filter fume containing potentially hazardous particulate and gases generated during manufacturing processes. Such hazardous substances are captured within a multi-stage filtration system after which the cleaned air is returned to the workplace.

  • Page 15: 4�6� Cabinets

    The supply cord should DANGER only be replaced by a Donaldson BOFA engineer as an electrical safety test may be required after replacement. The system MUST be connected to a properly earthed outlet.

  • Page 16: 4�10� Optional Added Features

    Donaldson BOFA 4�10� Optional added features The system can be configured to suit customer specification. These optional features would be discussed, arranged, and installed prior to delivery. If unsure what features your system is equipped with, please contact the seller with the extraction system serial number (refer to section 2 for location), who will be able to advise what specification has been supplied.

  • Page 17: 4�10�4� Override (Optional)

    AD 500 iQ User Manual 4�10�4� Override (optional) Enables the extraction system to operate fully with or without either DC voltage input or the volt-free input. The override feature can be toggled on/off by a switch mounted on the internal blower access panel (see picture on the right for switch location).

  • Page 18: 4�10�6� Compressor (Optional)

    Donaldson BOFA 4�10�6� Compressor (optional) If a compressor has been fitted to the extraction system, connect the compressor hose to the system compressor outlet (refer to section 1 for location), and connect the opposite end to the host machine (refer to host machine installation instructions). A water trap should be fitted to the host machine end of the pipework.

  • Page 19: Operation

    AD 500 iQ User Manual Operation 5�1� Turning extraction system on There are two stages to powering up your iQ extraction system. The on/off switch must be switched to the “on” position (refer to section 1 for switch location). This will place the extraction system in standby mode, indicated by the front panel power button illuminating red.

  • Page 20: Setting The Desired Airflow

    Donaldson BOFA 5�3� Setting the desired airflow The iQ system features automatic flow control. This enables the user to set the required airflow rate, then over time, as the filters begin to block, the blower will automatically begin to increase in speed to compensate for any loss in performance caused by the added restriction of the partially blocked filters.

  • Page 21: Maintenance

    AD 500 iQ User Manual Maintenance 6�1� Maintenance UK It is a legal requirement, under regulation 9 of the COSHH regulations, that all local exhaust ventilation systems are thoroughly examined and tested at least once every 14 months (typically carried out annually). The approved code of practice recommends that a visual check should be carried out at least once a week.

  • Page 22: Pre-Filter Replacement

    Donaldson BOFA 6�2�2� Pre-filter replacement Refer to section 2.2 for PPE requirements. The pre-filter needs replacing when the display flashes between the two images shown below. At this point, the buttons will illuminate red and if fitted the filter blocked signal will be given.
  • Page 23 AD 500 iQ User Manual To remove and replace the combined filter, follow the procedure detailed below. 1. Isolate the electrical supply to the extraction system. 2. Undo the latches on the front of the extraction system and open the door. 3.

  • Page 24: Intelligent Operating System (Iq) Display

    Donaldson BOFA Intelligent Operating System (iQ) display 7�1� Visual alarms on the iQ system The iQ system can visually display a range of alarms on its LCD panel. The visual displays, meanings, and solutions are detailed below. All alarms will trigger the system alarm interface output signal and the inbuilt audible buzzer if fitted/activated.

  • Page 25: Gas Filter Monitoring - Voc Sensor (Optional)

    If the VOC level in the exhaust exceeds the PPM (parts per million) level pre-set at Donaldson BOFA, the carbon within the filter is saturated and this will trigger the gas alarm and display the gas icon as shown.

  • Page 26: Usb Connectivity

    Donaldson BOFA 7�2� USB connectivity The iQ system is equipped with a USB port that operates as a two-way device, as detailed below. Duplicating iQ data Downloading iQ data This USB upload feature is intended for customers who have Customers can download all stored data within the iQ system...

  • Page 27: Event Log

    AD 500 iQ User Manual 7�2�1� Event log The iQ system will take a snapshot of the system performance every fifteen minutes, or if a system adjustment is made, or an alarm is triggered. Some of the information captured is listed below: Date and time The date and time will be set as part of the testing stage with the manufacturer and set to GMT.
  • Page 28 Combined filter blocked 8192 Pre-filter blocked 524288 System 75% blocked Faults This column will display a code if a fault with the iQ system is detected. For analysis of any faults in this column, please contact Donaldson BOFA technical service.

  • Page 29: Troubleshooting

    Faults are displayed as a number in the error window within the display. In the event of an error code being displayed, please contact your local representative or Donaldson BOFA who will be able to diagnose the fault and advise on the most efficient solution.

  • Page 30: Replacement Parts

    12 months. To maintain performance, it is important that the filters are replaced with identical Donaldson BOFA filters. To reorder, please refer to the filter number printed on the filter installed in your extraction system. See part numbers below: 1.

  • Page 31: System Specifications

    AD 500 iQ User Manual System specifications Extraction system: AD 500 iQ Size: Imperial (inches) Metric (mm) Flowrate minimum: 88 cfm (150 m Height 47.4 1205 Flowrate maximum: 324 cfm (550 m Width 24.4 Weight: 292 lbs (142 kg) Depth 31.1 Airflow measuring system: Windvane Suction pressure: 100 mBar Filters:...

  • Page 32: Contact Information

    Donaldson BOFA Contact information Donaldson BOFA head office – UK & ROW: Tel. +44 (0) 1202 699 444 19-20 Balena Close Email: Creekmoor Industrial Estate bofasales@donaldson.com Poole Dorset BH17 7DU United Kingdom Donaldson BOFA German office: Email: bofavertrieb@donaldson.com Donaldson BOFA US office: 303 S Madison Street Tel. +1 (618) 205 5007 Staunton, Illinois Email: bofasalesus@donaldson.com...

  • Page 33: Inspection Record

    AD 500 iQ User Manual Inspection record Inspection Record Local Exhaust Ventilation System Health & Safety at Work Act 1974 - Control of Substances Hazardous to Health - Regulation 9 (2002) Thorough Examination and Testing of Local Exhaust Ventilation Systems Company: System Designation: System Installation Date:...
  • Page 34 Process enclosure, extract offtake(s), hose/ducting, and extraction system. Inspection and Maintenance Record 1. Daily inspection Inspection of the process to ensure extract devices/nozzles/enclosures/hoses are in place and correctly positioned. Examination of the extraction system to ensure it is running. This to be carried out by the operator. Daily inspection not recorded.
  • Page 35 Weekly inspection by supervisor of physical condition of extract devices/nozzles/enclosures/hoses and extraction system for damage, change (parts added or removed) and correct operation, etc. Check also that daily inspections have been completed. Tick boxes to confirm system ok/change. Add details of any changes. Report changes to Engineering Manager.
  • Page 36 Process enclosure, extract offtake(s), hose/ducting, and extraction system. Inspection and Maintenance Record 3. Monthly inspection In addition to weekly checks, disconnect hoses and check for blockage and smooth operation of fan, signs of dust or vapor/gas/ odor carry over. Tick boxes to confirm system ok/change. Add details of any changes. Report changes to Engineering Manager. Record any remedial actions taken.

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