New manual V6 - Clearvueoz.com.au

Transcription

Assembly instructions
for your
CVMAX or CV1800
Compliance Training Australia Pty Ltd
157 McKenzie Street,
Dayboro Qld 4521
Ph: 0412 734 982
Web: clearvueoz.com.au
Table of Contents
Required items............................................................................................... 3
Tools ............................................................................................................ 1
General Items ................................................................................................ 1
Installation time ............................................................................................. 1
Getting to know your cyclone ........................................................................ 2
Specifications................................................................................................. 2
Unpacking the components .............................................................................. 3
Impeller housing carton (66mm x 61mm x 25mm) ............................................ 3
The cyclone body carton (51mm x 51mm x 132mm) ......................................... 5
The motor carton (31mm x 42mm x 36mm) ..................................................... 7
The VFD carton (27mm x 35mm x 25mm) ........................................................ 7
Assembly Instructions ................................................................................. 10
Step 1: Check the proposed placement ............................................................. 9
Step 2: Build and mount the Wall Bracket ......................................................... 9
Step 3: Assemble the motor mounting components .......................................... 13
Step 4: Prepare and mount impeller to the motor ............................................. 16
Step 5: Hang the motor and impeller assembly ................................................ 21
Step 6a: Assemble and fix the impeller housing if no filters ............................... 21
Step 6b: Assemble and fix the impeller housing if using filters ........................... 23
Step 7: Attach the impeller housing to the cyclone body ................................... 27
Step 8 Install the intake transition .................................................................. 29
Step 9: Assemble filters ................................................................................ 31
Step 10: Clean out box ................................................................................. 31
Step 11: Connect filter stack to cyclone ......................................................... 33
Step 12: Install collection bin ........................................................................ 33
© Compliance Training Australia Pty Ltd 2014
Required items
Tools

9/16” spanner

7/16” spanner

3/32” Hex key

Screw driver

Drill

Drill bits

Spirit level

Ladder

Tape measure or long rule
General Items

Rubbish bin or other container capable of being made airtight

Timber and fastenings for wall bracket

Duct tape or caulk
Installation time
Assembly and installation of your Clearvue Cyclone should take between 4 and 6
hours with two people.
Installing ducting varies enormously depending on your workshop size, the number
of machines and the complications of the duct routing scheme.
ABN: 73 12 54 698 898
www.clearvueoz.com.au
157 McKenzie Street Dayboro Qld 4521
stephen@clearvueoz.com.au
0412 734 982
Page 1
Getting to know your cyclone
*Items are not included and may be purchased separately.
Specifications
Item
Description
CV1800
Footprint: 600mm x 600mm or 600mm x 1050mm if using filters,
Maximum air flow through 6” (150mm) pipe 1442 CFM
CVMAX
Footprint: 600mm x 600mm or 600mm x 1050mm if using filters,
Maximum air flow through 8” (200mm) pipe 1935 CFM
Teco Motor
3 Phase 3 KW 2 pole Monarch series
Impeller
Backward Inclined Material Handling Impeller complete with taper lock
bushing. 406mm diameter for CVMAX, 381mm diameter for CV1800
Blower Housing
3/4” MDF Board Top and Bottom with 1/8” clear PETG plastic wrapper
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Unpacking the components
The Cyclone will be delivered to you in several cartons.
A standard configuration unit will consist of 3 cartons.
If you have ordered a VFD (Variable Frequency Device) this will be in a separate
carton.
If you have ordered filters these will be in two additional cartons.
You may have ordered accessories such as Blast Gates or Flexible hose. Such items
are usually able to be packed in one of the standard boxes to save freight.
Impeller housing carton
(66mm x 61mm x 25mm)
Contents:
Impeller housing includes:

the motor plate

6 x motor plate locking plates

the impeller complete with taperlock

the cyclone mounting plate
If filters were ordered the 900 transition for the outlet to the filters will be in this
box.
Unpacking tips
We advise you to open one end of the box and remove the flat box containing the
cyclone mounting plate before lifting the box onto a bench.
The impeller is held inside the housing assembly by a transit bolt through the
centre and a piece of MDF. This piece is disposable once unpacked.
If you remove the 6 motor plate locking plates the motor plate will then be free.
Remove it and dispose of the packing inside the housing. Remove the transit screw
and carefully lift the impeller out of the housing.
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Impeller housing assembly, Motor plate
& Impeller with taperlock
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Cyclone mounting plate
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The cyclone body carton
(51mm x 51mm x 132mm)
Contents:
The cyclone body.
Short section of flexible hose with clips to connect to the collection bin (bin not
included).
Clear inlet transition to join up with collection duct.
Clear straight outlet transition used where no filters are specified. Machines
purchased with filters will have a 90o transition included.
Hardware components include:

8 x rubber grommets

4 x ½ Pan Head screws (intake chute)

6 x 1 5/8” Blower Housing Screws

4 x 1 ¼” Transition Screws

8 x ¼ x 20 Lock Washers

28 x ¼ x 20 Flat Washers

24 x ¼ x 20 Nuts

4 x ¼ x 20 x 7” Threaded rods

4 x ¼ x 20 x 1 ½ Hex bolts (transition bolts)
Unpacking tips
We advise you to open the top of the carton and remove the loose items setting
them aside for later.
Depending on how tall you are, you may need to lie the carton down before
removing the cyclone body. Remove the cardboard spacer that is fitted around the
narrow end of the cyclone. (This is actually the base of the cyclone but is at the top
of the carton since the cyclone is packed upside down for stability.)
Carefully slide the cyclone body from the carton. It is best to leave it upside down
for now.
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The motor carton
Contents:

The motor

4 x M12 x 50mm High tension Bolts

4 x M12 Lock washers

4 x M12 Flat washers.

1 x motor shaft key
Unpacking tips
We advise you to move the motor carton with care as it is heavy – 29 kilos.
Remove the packet containing the four bolts nuts and washers. These will be used
to fix the motor to the cyclone mounting plate.
Remove the motor key also contained in the bolt package if it has not already been
fitted. Keep this safe as you will need it when you mount the impeller.
The VFD carton
This carton contains the Variable Frequency Unit and the manufacturer’s instruction
book. This book is a little daunting as it contains all the information that an
electrical/electronic engineer could possibly need to use the device with any type of
application. It also contains details for all the models that the company make.
If your order includes a VFD, in an envelope at the back of this manual is a
Clearvueoz manual specifically for the VFD when used with one of our cyclones. We
have developed this publication to assist you in programming and using your VFD
with your ClearVue Cyclone.
Please remember that the Law in Australia requires that these types of devices
ONLY BE INSTALLED BY LICENSED ELECTRICIANS.
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Page 7
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Assembly Instructions
Step 1: Check the proposed placement
Prepare the site where you will be installing your cyclone. If there are any space or
placement issues, please contact our office so we can assist you.
It is a good idea to mark out where the various components will go and make sure
there are no obstructions like wiring or pipes.
Remember that sharp bends in ducting constricts airflow and reduces the efficiency
of the unit. Try to locate the unit taking into account the following:

Minimise the duct runs

The possibility of a separate sound insulated space

Close to suitable power supply

Easy access to outside if filters not being used

Strong structure to mount to.
Step 2: Build and mount the Wall Bracket
Cut the bracket components
Instruction
Size for CV1800
Size for CVMAX
Cut 2 vertical pieces from
50mm x 100mm timber
245mm long
245mm long
Cut 2 horizontal pieces from
50mm x 100mm timber
460mm long
510mm long
Cut 1 Bracket back from
19mm plywood
310mm x 660mm
310mm x 660mm
Cut 2 bracket sides from
19mm plywood
241mm x 495mm
241mm x 546mm
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Join the vertical and horizontal pieces
Using two #12 x 65mm or longer screws, join the vertical (shorter) pieces to the
horizontal (longer) pieces by driving the screws through the vertical member into
the end grain of the horizontal member.
You now have two L shaped brackets. Pencil mark these as LH and RH
Attach the two side pieces
Taking the LH bracket glue one side onto the LH side. Reinforce the join using 4 x
40mm screws on the vertical piece and 6 x 40mm screws on the horizontal piece.
Taking the RH bracket, glue one side onto the RH side. Reinforce the join using 4 x
40mm screws on the vertical piece and 6 x 40mm screws on the horizontal piece.
Attach the back plate
Take the back plate and line up the LH bracket so the side is flush with the LH edge
of the board, and the top of the vertical piece is flush with the top of the back
plate. Glue the two parts together and reinforce the joint with 6 x 60mm screws
from the back of the back plate into the vertical piece. Then do the same on the
right side making sure the side is flush with the right side of the back plate and the
top of the vertical piece is flush with the top.
Mount bracket assembly to wall
The top of the bracket assembly should be at least 2400 above the floor which
allows a collection bin 710mm high. If you have a taller bin you will need to
increase the height of the bracket assembly by the height above 710mm.
If you cannot get the required height see addendum A at the back of this manual.
Use at least 8 #12 x 75mm screws and drive these into studs or solid supports.
These screws take the entire weight of the machine – it does not rest on the bin.
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Wall Bracket assembled
RH side panel
Back panel
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Step 3: Assemble the motor mounting components
Assemble the threaded rods and attach to motor plate
There are four threaded rods which are used to suspend the blower housing below
the motor. The components you need are:

The round motor plate

4 x threaded rods

12 x flat washers

12 x nuts

4 x rubber grommets

4 x lm lock washers
Thread the components onto each rod in this order
:
a.
1 x washer followed by 1 x rubber grommet. The washer should
be approximately 100 mm from the one end of the rod. This end
will be the top end when you fit the rod to the motor plate later.
b.
2 x nuts up to the washer but do not tighten the lock washer
yet. These lock nuts can be tightened later to compress the
rubber grommets,
c.
1 x nut only up about 15mm,
d.
1 x lock washer up to the nut,
e.
1 x flat washer up to the lock washer,
f.
Repeat steps a. to e. for the remaining 3 rods.
You should now have 4 threaded rods set out as shown opposite.
Place the motor plate onto a work surface with the T-nuts facing down. Insert the
threaded rods into each of the holes in the motor plate making sure that the flat
washer and lock washer remain in place.
Thread the rods in until they are almost flush with the base of the motor plate.
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¼” Threaded rods
¼”
Nuts
¼” Flat washers
Rubber grommets
¼”
Lock washers
Assembled rod before fitting to motor board
Motor plate with threaded rods
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Join the cyclone mounting plate and the motor plate
The cyclone mounting plate is the large blue MDF board with reinforcing bars on
each long side. These reinforcing bars must face upwards when the cyclone
mounting plate and the motor plate are joined. They will also face the ceiling once
the installation is complete.
Keeping the reinforcing bars facing upwards, lower the cyclone mounting plate on
to the threaded rods.
Thread the components onto each rod in this order :

1 x flat washer should rest flat on top of the cyclone mounting plate,

1 x rubber grommet,

1 x flat washer,

2 x nuts up to the washer, tighten the lock nuts so they are snug
against the flat washer but do not cause the grommets to bulge.
NOTE
After the cyclone is hung and fully assembled this pair of nuts will be used to level
the unit. The bottom nuts will be used to compress the bottom rubber grommets.
Prepare the motor
Stand the motor up so the shaft is pointing upwards.
Check that the half round key that is the standard fitting for the Teco motor has
been removed. This key will not fit into the bearing on the impeller. If not removed,
use a hammer and screw driver to remove it and discard.
Check that the electric box has been fitted so it will clear the cut out in the cyclone
mounting plate. If not, remove the screws and remove the lid. You will then be able
to unscrew the box from the motor and re-fasten once you have turned it through
900.
Invert the cyclone mounting plate and motor plate assembly and lower over the
motor. Install the 4 motor bolts using a flat washer and a lock washer on each bolt.
Tighten the bolts securely.
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order of components above Cyclone mounting plate
Cyclone mounting plate
Complete assembly
Motor showing wire outlet aligned correctly and correct motor key fitted
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Step 4: Prepare and mount impeller to the motor
The impeller can be installed onto the motor either before or after the motor
assembly has been hung in the bracket. The following table shows the pros and
cons of each method.
When to install
Pros
Cons
Before
It is easier to join the
impeller to the motor.
Increases the weight of the
motor assembly when hanging it
in bracket.
We recommend at least 2 people
to hang the completed
assembly.
After
Hanging the motor unit will
be easier but may still
need 2 people.
It is more difficult to mount the
impeller as it is hard to hold its
weight and work from
underneath against gravity.
This document concentrates on mounting the impeller before hanging the motor
assembly.
Prepare to use the impeller taperlock
The impeller is mounted onto the motor shaft using a Maska tapered bush. This
ensures that the impeller remains centred and firmly attached.
Opposite is a copy of the MASKA leaflet.
The Maska taperlock is supplied loosely fitted to the impeller and needs to be
removed before proceeding any further.
You will see that there are 6 holes in the taperlock. 3 are plain and three are
threaded. The plain holes are used to hold the two parts of the taperlock together.
These are the holes into which the bolts are lightly fixed when delivered. The other
three holes are used if you need to remove the taperlock from the motor shaft.
To do that, take the bolts out of the plain holes and insert them into the threaded
holes. Tighten progressively until the top part detaches from the impeller part.
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MASKA leaflet
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Position the impeller
1. Stand the motor, motor plate and cyclone mounting board with the
motor shaft facing upwards.
2. Take the motor shaft key and insert it into the keyway on the shaft. It
should be a tight fit.
3. When shipped, the impeller is temporarily fastened into the housing by
a MDF shipping plate. If you have not already done so, remove this
plate and discard together with any other packing.
4. Lift the impeller out of the housing.
5. Remove the shaft part of the taperlock as described in the “Prepare to
use the impeller” section.
6. Place the impeller over the motor shaft.
7. Place the shaft part of the taperlock over the motor shaft and align the
plain holes in the taperlock with the threaded holes in the impeller part
of the taperlock.
8. Insert the 3 bolts through the larger holes in the shaft part into the
threaded holes in the impeller part.
9. Lift the impeller so that the top of the taperlock is flush with the tip of
the motor shaft.
10. Tighten the bolts in a circular fashion round the taperlock. Continue
until they are all tight.
As you tighten, you will find that the impeller is drawn towards the
motor. When you get back to the first bolt, it will be loose until you have
been round the circle sufficient times.
When completely tight, there should be at least a 7mm gap between the
impeller and the mounting plate bolt head. If there is, loosen the bolts
and re-start with the top of the taperlock just past the tip of the shaft.
The required torque is 5 ft/lbs – 2.27 kg/f.
11. Tighten the setscrew against the key.
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Step 5: Hang the motor and impeller assembly
For this part of the assembly process you will almost certainly need
assistance!
Turn the motor and impeller assembly over so that the impeller faces downwards.
Lift the assembly and slide the cyclone mounting board onto the wall bracket you
fastened earlier.
Before you operate the cyclone you will need to fasten the cyclone mounting board
to the brackets. Do not do this yet as some minor adjustment may be needed as
you fit the rest of the cyclone parts.
Step 6a: Assemble and fix the impeller housing if no filters
Follow these instructions if you are not using filters otherwise ignore this section
and go to “Step 6b Assemble and fix the impeller housing if using filters”
Attach the straight transition to the Impeller Housing
Loosen the front 4 bolts on the impeller housing and ease it slightly open.
Place the two wooden pieces supplied onto the housing and re-tighten the bolts.
Place the straight transition square end over the opening and line up the bolt holes.
Place a flat washer on a bolt and then insert from the inside so that the bolt head
remains inside and the nut will go on the outside.
Thread onto the bolt a flat washer followed by a lock washer then a nut and tighten
gently.
Repeat the process for the other three bolts.
Apply silicone sealant to all 4 sides of the transition.
It is important to completely seal these joints – if not, fine dust may escape and
pollute your work place before being exhausted outside. The air being exhausted is
moving very fast.
Proceed now to page 28 - section 7: Attach the impeller housing to the
cyclone body.
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Motor and impeller on bracket
US motor shown
1
2
3
4
Sequence of assembly straight transition
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Step 6b: Assemble and fix the impeller housing if using filters
Assemble right angle transition
The transition is supplied as a flat pack consisting of:

1 x round base plate

2 x grooved side pieces

1 x short clear panel

1 x longer clear panel.
Insert the clear panels into the grooves on the two side pieces.
Insert the assembly you have just created into the slot in the round base plate.
Drill 4 small pilot holes into the round base plate to line up with the base of the two
side pieces.
Attach the assembly to the base plate using the four screws provided. Take care
not to split the side pieces.
Apply silicone sealant to the junction of the clear panels and the side pieces.
Apply silicone sealant to the junction of the side pieces, clear pieces and the round
base plate.
pollute your work place before reaching the filters. The air being exhausted is
moving very fast.
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2
1
4
3
Construction of right angle transition
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Attach the transition to the impeller housing
Important
Do not remove the white piece of wood located in the impeller
housing. This piece operates as a sound damper as the blades pass by the opening
of the impeller housing.
Loosen the front 4 bolts on the impeller housing and ease it slightly open.
Slip the transition into the impeller housing.
Re-tighten the front 4 bolts clamping the transition in place.
Ensure the transition is square and level where it meets the housing, and drill
through the holes in the side pieces.
Place a flat washer on a bolt and then insert from the inside so that the bolt head
remains inside and the nut will go on the outside. It is fiddly to fit the bolt from
inside but causes less turbulence and interruption to airflow.
Thread onto the bolt a flat washer followed by a lock washer then a nut and tighten
gently.
Repeat the process for the other three bolts.
Apply silicone sealant to all 4 sides of the transition.
pollute your work place before being exhausted through the filters. The air being
exhausted is moving very fast.
Instructions for assembling and attaching the filters is dealt with later in
this manual at Step 9 onwards. Please continue with Steps 7 and 8.
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Step 7: Attach the impeller housing to the cyclone body
You need to decide where the intake and outlet transitions should face. You can
rotate the impeller housing to achieve the desired outlet position. You can orientate
the cyclone body to set the intake transition at the required position.
Before progressing further you will need to prepare a support for the cyclone body.
We recommend that you use a bin or strong box to stabilise the body whilst you fix
the housing to it. You will then need a temporary support while you join the
impeller housing to the motor assembly. It is often possible to create this by
placing a board over the bin you have already used.
If you want to seal all the seams in the impeller housing it is easier to do this now
using silicone sealer.
Check the desired position of the exhaust transition.
Place the cyclone body into a container to stabilise it while fixing the impeller
housing.
Check where the inlet transition needs to face to make connecting ducting easy and
as smooth as possible.
Attach the cyclone body to the impeller housing using the 6 x 1&5/8” screws
provided. DO NOT OVERTIGHTEN THE SCREWS or you could crack the cyclone
body.
Remove the cyclone body with the impeller housing attached and support it under
the hanging motor and impeller assembly. Using packing pieces, lift the cyclone
body until the impeller is in place inside the impeller housing.
Install the 6 locking plates on the impeller housing. At this stage, leave them
slightly loose in case you need to move the unit whilst completing the installation.
Note: the motor plate may not sit flush with the top of the impeller housing - this is
normal.
Use a spirit level to make sure that the cyclone is level. Adjust the nuts on the
threaded rods to level if necessary.
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Step 8 Install the intake transition
It may be easier to rotate the cyclone body for better access.
Slide the intake transition into the hole in the cyclone body.
Attach the transition with the 4 #6 x 3/8” screws provided.
Seal the joins of the transition with silicone sealant.
Rotate the cyclone body into its permanent position and firmly tighten the 6 x
locking plates on the top of the impeller housing.
Re-check the cyclone body is level and re-adjust if needed.
Secure the cyclone mounting board into the wall bracket using either 35 mm
screws or suitable bolts.
Pre-drill the holes to avoid any spitting.
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You may see a small black
grommet near the intake. This serves to
prevent dust from collecting in the
dead space inside the cyclone body.
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Step 9: Assemble filters
Stack one filter on top of the other.
Apply a thin bead of silicone on the outside of the join between the two filters
Take the band clamp supplied and assemble if needed. The two flanges are held
together with a bolt.
Place a flat washer on the bolt and insert it through the flanges.
On the outside of the second flange thread a flat washer then a lock washer.
Loosely fit the wing nut supplied.
Slide the band clamp to cover the join in the two filters and tighten lightly using the
wing nut.
Step 10: Clean out box
If you are using filters you need a clean out box at the bottom of the filter stack.
This enables you to collect any small quantities of dust which may come from the
filters when they are cleaned.
To clean the filters gently vibrate the filter stack. This should not be necessary very
often and will depend on the type of work you do and how often you use the
system.
Clearvueoz offer a custom made clean out box as an accessory. Alternatively you
can make your own.
There are only a few requirements for the clean out box:

It should be at least 36 cm square or round.

It must be airtight except through the filter inlet.

It needs a sealed opening to allow the contents to be extracted. We
recommend a flange with lid suitable to connect a vacuum hose to.
The height can be determined by standing your filter stack under the transition and
measuring the gap. This will then be the desired height for the box. Alternately you
can insert packing under a shorter box.
To install the clean out box simply stand the filter stack on the box and apply a thin
bead of silicone sealer around the join between the box and the filter stack.
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Filter clamp
Filter Stack
Clean out box available for
Purchase from Clearvueoz.com.au
Example home-made dust collection box
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Step 11: Connect filter stack to cyclone
Slide the filter stack with the clean out box attached under the filter transition. The
assembly should be a snug fit. If there is a gap, use packing pieces to close the
gap.
Drill pilot holes in the MDF plate at the base of the transition.
Attach the filter stack using 35mm #6 sheet metal screws.
Either cover the join with a good quality duct tape or apply a thin bead of silicone
sealant around the join.
Step 12: Install collection bin
There are many possible alternatives which you can use to act as a collection bin.
There is only one golden rule – It must be airtight!
Other considerations include

Weight of the finished item.

Ease of moving and emptying.

It must be sufficiently rigid to not collapse under the suction.

Maybe the ability to know when it is full or getting full.
Alternatives include:

A galvanised rubbish bin – you will need to modify the lid.

A heavy duty plastic bin – you will need to modify the lid.

A wheelie bin – You will need to make a new lid and check the bin is
airtight.

A steel barrel eg 44gal drum – you will need to modify the lid.

A cardboard drum – You will need to modify the lid.

Construct your own design of box – beware you do not make it too
heavy to move easily for emptying.
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Note: the photograph shows an
older filter with a square joining
plate.
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Modify or make a lid
Metal lids
The most common situation where you will need to modify a metal lid is where you
are using a metal rubbish bin or a steel drum.
You need to create a hole 150mm in diameter.
This hole will normally be in the centre of the bin but if you need to offset it due to
location challenges this is not a problem.
There are 2 simple ways to fix the short hose from the bottom of the Cyclone body
to the lid.
a.
Simply cut a hole and silicone seal the hose to the lid.
b.
Fasten a flange joint to the lid and slip the hose over this.
If you are using silicone sealer and no flange

Using a drawing compass or a suitable sized template, draw a circle
150mm in diameter in the location where you want the hole. (drawingcompass is set to 75mm radius)

Inside that circle, use the same centre but only120mm in diameter.
(drawing-compass set to 60mm radius)

Using your tool of choice eg: tin snips, jigsaw or multi-purpose cutter,
cut out the smaller circle

Make a series of cuts (between 15 and 20 works best) from the edge of
the hole you have created straight out as far as the outer marked circle

Using pliers, bend the tabs you have created upwards to form support
for the inside of the hose

Place the hose provided over the tabs and seal with silicone generously
applied both inside and outside the lid

Apply a dust sealing tape around the perimeter of the lid to sit between
the lid and the bin sides.
ABN: 73 12 54 698 898
0412 734 982
Page 35
Lid showing tabs folded up
Hose slipped over tabs
ABN: 73 12 54 698 898
0412 734 982
Page 36
If you are using a pre-formed flange joint

Using a drawing-compass or a suitable sized template draw a circle
150mm in diameter in the location where you want the hole (drawing
compass is set to 75mm radius)

Using your tool of choice eg: tin snips, jigsaw or multi-purpose cutter,
cut out circle

Check that the hole you have made allows the flange to slide through –
if not, enlarge the hole slightly

Apply a generous amount of silicone sealant to the top of the flat plate
of the flange

Pass the flange through the hole and press firmly into the underside of
the lid

Apply more sealant around the lid where the flange protrudes

Place the hose provided over the insert and use one of the bridge
clamps supplied to hold it tight against the insert

Apply a dust sealing tape around the perimeter of the lid to sit between
the lid and the bin sides.
ABN: 73 12 54 698 898
0412 734 982
Page 37
Inside of lid showing dust sealing tape
Example pre formed flange
ABN: 73 12 54 698 898
0412 734 982
Page 38

New manual V6 - Clearvueoz.com.au

Transcription

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