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Weld Station LEAF User Manual

1. Detail L Remote Start Stop Terminal Strip Wiring Valve 2 Valve 1 Motor Power To Light 70 50 Dirt 1 The wire diagram shows the wiring set up for a high voltage 460VAC three phase system To wire the system as a low Junction To Motor mend 80 Incoming voltage 230VAC or 208VAC three phase system see the transformer diagram in Detail F and motor wiring in Details D amp E Box Mount 20 eu Air Line Power run Different drives are required for 460VAC and 230VAC Different Drives are used for high and low voltage 45 SKD SKD To air fitting by BS 60 4 pea Motor customer 2 Fork Termi
2. 76 How to replace filters Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 77 APPENDIX A FILTER MAINTENANCE LOG SHEET 81 APPENDIX B DIMENSIONAL DRAWINGS 82 APPENDIX C EXPLODED TC 101 APPENDIX D WIRING DIAGRAMS MARCH 2011 3 112 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 SHIPPING RECEIVING AND I NSPECTI ON RECEIVING AND INSPECTION Congratulations on the purchase of your new Clean Air America Weld Station System 22 Upon receipt of the Weld Station remove the master packing list from the unit and reconcile it with the total shipment za 22 Report any discrepancies to Clean Air 28 America as soon as possible me A _ N 22 Clean Air America s Weld Station units are W d e shipped via freight and generally arrive on a flat bed trailer The main units are partially crated on a pallet and are shipped laying on their sides
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4. n dee Pu al ee de gt Lon n LE Pa af L mas Cd Slide the first dust tray all the way to the if Lie SE Ce L Z left of the filter compartment 2 Slide the first dust tray down to the floor of the catch area It should be sitting below the corner of the slanted panel so that dust is directed into the dust tray Slide the second dust tray under the front Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 40 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 filter rings which support the front two filters z Slide the second dust tray all the way to oe rrr We e ET d Zei the right of the filter compartment b it ii A Y A z Slide the first dust tray down to the floor of the catch area beside the first dust tray Swing the filter door closed cd Place a 3 8 zinc flat washer on each of the lever handles Place the threaded stud of the lever handles through the holes in the filter door arms 2 Screw the lever handle into the weld nut and tighten the door down AIR MERICA INC ling Smoke Removal Lamm Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 INSTALLING THE HOLE PLUGS 2 Once the unit is fully assembled and opera
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6. ee EREx SE AVERERVE ER TET EvETE UR pev LEY T ev 45 PAR REGU TOR uuu uuu 45 AS RE N OE EN 45 Big e u e A II EEE E E AET E A EE AE T E EEE T E 46 TVEN 46 ELECTRICAL CONNECTIONS sssssssssassasasasssassassssssasssssssasssssssssssssssasasasas 47 CONNECTING THE SECONDARY BOOTH LIGHT S sad cab tres odd auto IG 49 POWER DISCONNECT SWITCH EMERGENCY SHUT OFF SWITCH a 51 MODE SELECTOR NA 52 INTERLOCK NE 53 INTERCOCK NE 53 OH ISWI OE N OO u AE EO EEN 54 PRE 54 A EEE 55 WELD STATION LEAF FEATURES sscccsssccssscccsecccsscccsstcccssccesseccsstcccssccessccesstcccstccessscesstcccstccessecessscesaneecazecs 56 SFT 56 PETN 56 ECONOMIZER EE EE EE EE EE EE EE EE EE EE EE EE EE EE EE aaa 56 SE SE es e TNR 56 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 REDUCED NVIAJNII AN SR 57 REDLUEED NE 57 SYSTEM CONTROLLER sssssssssssssasssssssasssasssssssssssssss 58 II F CEFAN CONTROLS oe ee EG 59 PIO OD EE 60 MANUAL MODE TIMED iS es nes Gee SE Ge ee ee be GE bee GR Ge GE Ge ae Gee Ge dee Ge GE ee ee Gee ee Ge DE GE ED EG GE ER Ge GR Ge GR se DE ie e
7. Document CAA 00037 R001 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 TABLE OF CONTENTS TABLE OF CONTENTS eec 2 SHIPPING RECEIVING AND INSPECTION 6 RECEIVING ANID INSPECTION stc EE 6 BEFORE INSTALLATION BEGINS u l L u EE EG AE GER De a a S aqa Rak AEN AAAA A ENAR 7 WELD STATION DESCRIPTION ccccccecccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccceccsescccs 8 FEATURES AND SPECIFICATIONG cccscccssccssccssccssccnscesscesscensceusceuscenscenscessceuscesscessceusceusceusceussccsscessccssccssccssecs 9 GENERAEFEATORES RT 9 BLOWER MOTOR SPECIFICATIONS ccc u uu uuu Ee Ee ee iode ic deus ee lesus desee ee UN NR A E d DM DM POL DL M Rad 10 IL IT ei MEE ME N RE ME x di 10 INSTALLATION EN N EE N EE N EE OE NE EE ER N P 11 GENERAL INSTALLATION GUIDELINES Uu u u i oe eie SE eN ee ee TUR ee See ee iaa 11 TOOLS NENNE 12 Regured FOO ER 12 Optional Recommended Tools siii init 13 NETT DB RE 15 DUAL UNIT PARTS I uuu a ua N EE N EE N OE EE OE EE 17 WVARNINCS AND LABEL Su uuu uu EE EE OE EN 19 MOVING THE WELD STATION MAIN UNI 20 BRINGING THE MAIN UNIT UPRIGHT NO LIFTING Toon 22 BRINGING T
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10. Black Lever Handles 1 Electrical Box Key 2 3 8 Lock Nuts Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 I 2 Internal Panel Baffles pre 2 Table Slides pre installed 1 Welding Table installed m EN ege or DEM Sires waaka Puma Ze 3 Fi Sette Tries 2 i med LLL Mica A s Tez mas ae A z E aa b u 4 L dad E d l 2 Metal Mesh Spark Baffles 2 Reverse Flow Spark Baffles 3 19 x 27 Plenum Cover Plates Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 DUAL UNIT PARTS LisT The following parts are shipped with each Weld Station Dual one secondary booth attached to main unit Colors of some parts may very if a custom color was ordered Please confirm that all parts have been shipped before beginning assembly head cap screw 50 1 4 Black Nuts 4 Locking Hole Plugs 1 25 Roll of Flat Gasket 2 Black Lever Handles 1 Electrical Box Key 2 3 8 Lock Nuts Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 2 Internal Panel Spark Baffles if the secondary 4 Table Slides pre installed 2 Welding Table booth is 5 or 6 wide 3 Internal Panel Spark Baffles
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13. Station ei AT BEE Dar ce Properly sized chain or cable can be attached to a lifting tool on a fork lift truck The chain or cable can then be connected to the lifting lugs of the unit The forklift truck can then be used to lift and raise the unit 2 Other methods include attaching a chain hoist or come along or both to the eyelets provided at the top of the unit 2 When the unit is being lifted the bottom of the unit may shift If possible brace the bottom of the unit to prevent slipping C A 2x4 brace is fastened to the front floor flanges of the booth This used during shipment to prevent the collapse of the booth side walls This 2 x 4 should be kept in place while bringing the unit upright to prevent damage 2 SLOWLY hoist the unit up supporting it whenever and wherever possible Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 24 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 2 DO NOT let the unit slam suddenly when bringing the unit into the upright position This can cause damage to the unit c f risers are being used then attach the risers before bringing the unit upright See the Weld Station Accessories user manual for additional instructions Cd Please proceed cautiously WeldStation ef AMERICA INC Fl en TT rra 700 301 1700
14. The secondary booths are partially crated and shipped upright c Remove the packaging from the unit then remove the unit from the pallet Cd Carefully inspect the unit and any other items shipped with the unit for any damage that may have been incurred during shipping If damage is found report it to the shipping company and Clean Air America immediately Cd Weld tables spark baffles and dust trays if purchased are packaged and shipped inside the booth area of the main unit or secondary booth Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 2 The Reverse Flow and Metal Mesh spark Baffles require being shipped separately amp Accessories may be packaged and shipped on a separate pallet depending on the order In some cases these parts may be packaged inside the booth area of the main unit or secondary booth 22 A bolt package is included for each unit and booth combination This bolt package includes lever handles for the filter doors only of the main unit and flat gasket for the entire Weld Station assembly It is taped to the table slides inside the unit or booth BEFORE INSTALLATION BEGINS 22 Prior to using your Weld Station it must be fully assembled and placed in its final operating location Adequate electrical and compressed air must also be connected to the Weld Station These co
15. gt 2 La il NY NON GO I N HUN UIEN S UONEIS PISM LON UONREISPISM Copyright Clean Air America Inc Page 43 of 114 Weld Station User Manual March 2011 lt Q de S ded ac Uu 5 L gt lt lt EP c O KE d G lt O es Seg 7 Superior Drive 706 291 1700 866 665 1829 Rome GA 30161 UOIVULAO U1 ALOU 40f 1017288 101 22100 1021412914 PUD UOIIAS UOYIIUUO ALY passa4dui0 241 328 asvajg num 241 8uyps2do asofag 2ppu 240 SUOYDIUUOD 2824 fo yjoq mi 9ANS INDIA 100g Kappuosas up 07 4240d paaf ma pun nun 241 40f suogoauuoo JOUAIJXA uo IYJ AAD suogoauuoo UIDUL S 1 un uipu 241 fo do 241 uo UOIDIO 240 SUOYIJIUUOI ALY possa4duio PUD 2112214 UOI 298uuo 2 Hwy pessajduJo uoi euuo o2uj eH Y dr WA or K i gt lt gt Te pe Doc c DES NY WM MAYA N H SNAM HUN UIEN 9 UONEIS PISM LON Copyright O Clean Air America Inc Page 44 of 114 Weld Station User Manual March 2011 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 COMPRESSED AIR CONNECTI ON In order for the automatic pulse filter cleaning system to operate the Clean Air America Weld Station requires a compressed air connection to be made 22 The compressed air inlet is located on the top of the Weld Station in front of the exhaust panel This Weld Station com
16. long pieces are placed on the long sides of the cover plate These gasket pieces will be between the upper and lower gasket pieces and will cover the 2 bolt holes on each side of the opening The 4 gasket pieces must be placed centered over the bolt pattern 22 Once all four flat gasket pieces are placed there should be no gap between the gaskets 22 Once all four flat gasket pieces are placed then punch a hole into the gasket at each bolt hole to allow a bolt to pass through Be careful not to damage the gasket Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 INSTALLING THE COVER PLATES Any intake plenum opening not used for connecting the main unit to the secondary booth must be covered using one of the plenum cover plates 22 t may be necessary to install the cover plates before setting the units in the final location Obstructions such as walls or other Weld Stations my prevent or hinder access cd Flat Gasket must be installed on the main unit and booths before the cover plates can be installed 22 Align the cover plate blocking the intake plenum opening so that the bolt holes are aligned 22 Fasten the cover plate to the main unit or booth using 10 1 4 20 x 1 0 black socket head cap screw 20 black 1 4 flat washers 10 black 1 4 lock washers and 10 black 1 4 20 nuts The screw heads should be on the outs
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18. EMT fitting can be remove leave a female Rigid Metal Conduit RMC connection Cd When power is brought into the Weld Station through the EMT Conduit fitting it will enter the electrical box at the top of the box 22 First make the ground connection into the grounding terminal block 2 The incoming power wires must be terminated on the incoming side of the power disconnect switch emergency shut off switch L1 L2 L3 Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 47 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 Primary branch circuit protection must be provided by the end user The breaker must have an IC trip rating of 3OkA Please see the following chart for recommended breaker size 22 A wiring diagram for the Weld Station is provide in Appendix B cd The full load amperage varies depending on the unit configuration Please the following chart for motor and unit full load amperage ratings FLA 208V mies Phase Disconnect Incoming Power Incoming Power e Lem Size A Wire elsa Cable SO tin ak sr x4 5 mr zr so x 230V Single Phase Motor Size Motor FLA Unit FLA Disconnect Incoming Power Incoming Power e HP Size A Wire en Cable SO Settin ak 3 s ase o 5 28 296 50 208V Three Phase Motor Size Motor FLA Unit FLA Disconn
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20. It is located below the filters and below the filter door 22 Simply clean this area using a proper vacuum systems to remove the accumulated dust Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 Dusr TRAY MAINTENANCE NOTE Dust trays are an optional accessory and are not necessary for most operations If dust trays were not purchased see the Catch Basin Maintenance section If purchased there are two dust trays there are for each Weld Station main unit These dust trays are located in the filter compartment As the self cleaning cycle is activated dust will be blown from the filters and accumulate in the dust tray The Weld Station dust tray should be inspected and cleaned periodically The dust trays will acquire dust and debris require being emptied regularly The waste should disposed of in accordance with local regulations The inspection and cleaning interval depends on the amount of particulate generated in your specific application Variables can greatly influence the amount of particulate being deposited on the filters and in turn the dust trays Initially it is recommended that inspection of the dust trays be performed every four to six weeks on each machine This will give you an idea of how much particulate is falling into the trays and how often they should be emptied Most educational facilities empty their dust trays every t
21. Signal Pink 9 PHASE 1 d dd CE OS To Econ 1 o put 6 480VAC Phase 2 Switched 36 Automatic Signal Purple e e eto 3 Uv 7 480VAC Phase 3 Switched 37 Manual Override Signal Blue e e PHASE 2 elo 7 SACH a i 8 N A 38 VFD Run Command Signal Brown P sa seg EA gs erential 9 N A 39 VED Sleep Command Signal Green e e PHASE 3 gon BN S ms EE 10 N A 40 5VDC Supply e O Of 11 Valve 1 Signal 110VAC T V F Inc 120VAC Single Phase 3 3 34 35 3637 valve nacional VA pu EE ra trial Control P Ni 5 erme 34 E er Transformer cee Note 1 E di aa e Se geg gue Ems 35 Gps Mal e pecus G uper 24 iem See Ph 1 48 NA A Manufacturer No To 0 1 NC e 36 O 36 Ose Sockels Male Pins da Electrical 22 Motor 1 Power Ph 2 49 Safety Relay ON Signal Serial No See Electrical Panel To MAN 3 NO eil 37 _ Offre o empor Box Body a y o 7 oP O 27 480VAC Phase 1 Incoming 52 Trans Secondary O C P NOTE Remove Jumper Main Unit Secondary 28 480VAC Phase 2 incoming 34 36 Side Booth Side e 29 480VAC Phase 3 incoming Internal jumper inside O transformer Man 0 Auto Rotary Switch Detail C Slave Booth Connection To VFD input 53 9 To Main terminal block 4 To Co
22. WHOLE OR YAELECTRICAL DIAGRAMSICURRENTWELD STATION SERIES REV14 VSD Secondary Booth SA INC PERMISSION OF CLEAN AIR AMERICA STATION SHEET SIZE SCALE IDRAWN BY PAGE To first light in To second light Light Junction Box Detail E Low Voltage E INC IS STRICTLY PROHIBITED Electrical C TS 5 OF 10 Booth in Booth Motor Wiring
23. Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 25 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 MOVING THE SECONDARY BOOTHS zc fthe secondary or slave booth has NOT been uncrated then it can easily be moved by using a fork lift truck Place the forks under the pallet s main beams and simply lift the unit Make sure to lift the booths from the side of the pallet zc fthe secondary or slave booth has been uncrated then the booth can still be moved with a fork lift truck Place the forks under the bottom of the intake panel of the booth Card board or rubber padding can be placed on the forks to prevent scratching of the unit Do NOT place the forks under the lights Do NOT let the forks enter the intake at the back of the booth Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 26 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 INSTALLING THE FLAT GASKET ON THE UNIT Flat Gasket must be places around the outside of the plenum 5 CAR Ge opening before assembly This should only be done around the opening being mated to the secondary booth The flat gasket must be cut to length from the roll For each opening the following pieces should be cut 2 19 long and 2 2
24. being removed the type of filters being used and the type of welding being performed all effect the filter replacement interval Because of all of these factors the customer must monitor and document the system airflow readings for a period of time The information collected will help determine the most appropriate time to change filters This process will ensure that the system runs at maximum efficiency while minimizing filter replacement costs The easy access system of the Weld Station helps with faster filter replacement and reduced maintenance Where to Start Start by making copies of the attached log sheet This log sheet should be filled out for each Weld otation you have in your system Make a physical check to ensure that the smoke particulate is being removed through the intakes spark baffles This can be done by a simple visual check during normal operation There should be a reduced level of visible smoke when the unit is in operation During maintenance examine the intake spark baffle at the back of the welding booth s These filters should be washed when they become visibly dirty contaminated The differential pressure sensor does measure across intake spark baffles however visual inspection is required Replacement filter cartridges and spark baffles of all types are available from your Clean Air America sales representative How to Determine the Filter Change Interval At this point take note and document t
25. dust trays were purchased see the Dust Tray Maintenance section The catch basin is located in the filter compartment below the filters As the self cleaning cycle is activated dust will be blown from the filters and accumulate in this retention area The catch basin should be inspected and cleaned periodically as it will acquire dust and debris and will require being emptied regularly The waste should disposed of in accordance with local regulations The inspection and cleaning interval depends on the amount of particulate generated by the specific application Variables can greatly influence the amount of particulate being deposited on the filters and in turn affects the amount of accumulation inside the catch basin Initially it is recommended that inspection of this area be performed every four to six weeks on each machine This will give you an idea of how much particulate is being accumulated and how often it should be cleaned Most educational facilities empty their catch basins every three months to a year Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 To check and empty the catch basin simply open the filter door This is done by unscrewing the lever handles Make sure to retain the bearing washers 22 Swing the filter door open 22 In the bottom of the of the filter compartment is the catch basin
26. for the other metal mesh spark baffle however slide the second baffle all the way to the left Weld Station User Manual March 2011 Copyright Clean Air America Inc Innovation in Air Filtration 77052911700 866 665 1829 Page 34 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 6 Repeat steps 1 through 4 for the 2 Reverse Flow spark baffles placing first on the right and the second on the left NOTE Make sure when installing the intake baffles that they are installed in the correct direction On both the metal mesh and Reverse Flow spark baffles there are markings to show the proper air flow direction The arrows must point into the intake Additionally the Reverse Flow spark baffles must be installed so that the baffles are horizontal Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 REMOVING THE TABLE SLIDES Before the unit and secondary booth can be attached together the table slides of the adjoining walls must be removed The same bolt is used to hold the table slides of 22 Loosen and remove the 4 bolts holding the table slide onto the side wall of the booth or unit Retain these bolts Hold onto the table slide to support it while loosening the bolts and prevent damage due to fal
27. if the secondary booth is 3 or 4 wide pre installed 4 Metal Mesh Spark Baffles if the secondary 2 Reverse Flow Spark Baffles if the secondary booth is 5 or 6 wide 3 Metal Mesh Spark booth is 5 or 6 wide 3 Reverse Flow Spark 4 19 x 27 Plenum Cover Plates Baffles if the secondary booth is 3 or 4 wide Baffles if the secondary booth is 3 or 4 wide Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 WARNINGS AND LABELS HIGH VOLTAGE The voltage of the Weld Station is dangerous once connected to a power supply Incorrect installation may cause damage to the equipment serious injury or death Consequently it is essential to comply with instructions in this manual local and national safety rules and follow all safety Vv O LTA G E procedures including proper lock out and tag out procedures DISCONNECT POWER BEFORE SERVICING Hazardous Voltage The Variable Frequency Drive VFD DANGER MM ee Hazardous voltage uses large capacitors which can hold a charge long after the Devices inside this panel contain stored power disconnect has been used to disconnect power from the electrical energy Make sure Cadres are unit Do not service the panel until the VFD has fully properly discharged before servicing discharged GROUND CONNECTION Proper grounding of the equipment and electrical panel is essential D
28. the bolts on both the left and the right side of the baffle plate This should allow the baffle plate to fall free from the vertical supports 2 Reach into the intake opening and slide the baffle midway to the opposite side of the booth in front of the vertical supports 3 Rotate the baffle so that one side begins to twist into the back of the back of plenum area 4 Tilt the baffle plate at a 45 degree angle to remove it through the front intake of the booth 5 Repeat steps 1 through 4 with any other baffles Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 32 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 INSTALLING THE INTERNAL PANEL BAFFLES The internal spark baffles must be installed before using the Weld Station Internal baffles are located in both the main unit and secondary booth 1 Begin by tilting the baffle at about a 45 degree angle 2 Slide the baffle into the intake plenum through the intake opening Slide it in past the internal baffle support 3 Once the baffle is entirely inside the plenum area rotate the baffle so that it is vertical 4 Then slide the baffle forward in front on the intake supports 5 Once the baffle is vertical in front of the supports place it flush on the supports and slide it up so that the bolt pattern on the baffle is a
29. unit has shut down if the Shut Down Pulse Limit Shutdwn delP is reached while the unit is running During a shut down pulse the controller will pulse the valves for the specified number of cycles or Shut Down Pulse Cycles ShutDown Pls If the controller is going to perform a shut down pulse the display will read On Stop after Automatic Mode The controller will pulse while the unit is running if the Run Pulse Limit Run Pls delP is reached while the unit is running During a running pulse the valves will continue to pulse until the pressure differential has dropped below the Run Pulse Limit setting If the controller is performing a running pulse the display will read RunPulse after Automatic Mode If the controller performs a running pulse it will also perform a shutdown pulse If the Alarm Limit Alarm delP is reached while the unit is running the controller s front display will begin to flash This indicates that the filters are significantly clogged and may need to be changed MANUAL MODE TIMED This mode will pulse the valves one at a time in sequence until the timer has expired The Timer is in minutes To change the timer press the OK button The number of minutes will begin to flash Use the and buttons to increase and decrease the pulsing time respectively Press the OK button again to set the new time Press the A button to begin pulsing The pulsing can stopped by
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31. washers can be replaced when finished 5 Swing the door open to allow access to the filter compartment and reveal the cartridge filters 6 Release the first filter by loosening the filter clamp at the top of the filter This is done by rotating the metal T handle clockwise when viewed from below As the clamp spins it will release pressure from the filters Make Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 77 of 114 7 Superior Drive Rome GA 30161 sure to create a gap between the filter cap and the end of the clamp 7 Once the clamp has been loosened the filter can be accessed 8 Remove and set aside the filter cap Do not discard it 9 Slide a large plastic bag over the top of the filter cartridge and slide the bag over the filter to the bottom of the filter cartridge 10 Remove the filter in the bag and tie the end of the bag closed 11 Cover the filter duct and ring to avoid dirt or dust entering the clean air duct Make sure to cover the entire duct and filter ring A plastic bag can be used 12 Repeat steps 6 through 11 for the remaining filters 13 Clean each of the filter caps This can be done by simply blowing them off with a compressed air nozzle or wiping them clean with a dry cloth Make sure not to damage the gasket of the filter cap 14 Some excess dust and debris may need to be removed while the filters have been removed from the u
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33. 120 Volt AC single phase This is then branched to 24V DC for the controller LED lights and air sensors Breakers are marked on the electrical diagram There are 1 on the transformer secondary coil 2 on the transformer primary coils 1 on the terminal strip for the differential pressure sensor 1 on the terminal strip for the lighting circuit 22 The overload may need to be reset The Eaton overloads have an automatic reset function which is turned off If this has not been set the overload will require being reset via the red button marked Reset A unit can be wired for both High Voltage 460 VAC 3 Phase and Low Voltage 230 208 VAC 3 Phase The jumper s on the input H side of the transformer change depending on the input voltage For changing the wiring of the unit refer to the wiring diagram for jumper settings and motor wiring NOTE If the unit is being changed from High to Low Voltage or vice versa the contactor and overload may need to be changed This is because the lower voltage requires twice the amperage If the unit is being converted to low voltage the power wiring should be checked for proper gage wires The wiring in the motor connection must be changed as well Innovation in Air Filtration Clean Air America Inc www clean air com FAM AIR 7 Superior Drive 706 291 1700 MCA INC Rome GA 30161 866 665 1829 Wire numbers have been added to the wiring diagram to aid in both the di
34. 18 for the remaining filters 20 Close and secure the filter door Use the lever handles to clamp the door shut Weld Station User Manual March 2011 Copyright O Clean Air America Inc Page 79 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com AM AIR 7 Superior Drive 706 291 1700 A INC Rome GA 30161 866 665 1829 Make sure to use the 3 8 flat washers on the lever handles 21 Rotate the Emergency Stop Disconnect to the 1 or ON position This will restore power to the unit 22 Press the green START button and allow blower to spin up Some dust or debris may have fallen into the filter ducts this dues would then be blown out when the unit begins to run Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 APPENDIX A FILTER MAINTENANCE LOG SHEET Action Taken c 2 v di b a E de m c m 5 E E c n d D y val E 7 a val 2 m e c d m D o a c 9 amp d iL 1834 Cartridge Controller Reading Metal Mesh Reverse Flow Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 APPENDIX B DIMENSIONAL DRAWINGS Notes concerning the dimensional drawings 22 The secondary booths can be placed to the right or left of t
35. 22 Find the connectors and run them through the cable track to make a connection Multiple cover plates may need to be removed to properly run the connector cables Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 49 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com AM AIR 7 Superior Drive 706 291 1700 gt A INC Rome GA 30161 866 665 1829 22 Once the cables connectors reach each other simply press the male connector into the female connector to make the final light connection The connectors will only connect together one way 22 Any excess slack in the wire can be left loose inside the wire track 2 Once the connection is made replace all the wire track cover plates Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 POWER DISCONNECT SWITCH EMERGENCY SHUT Orr SWITCH This switch controls the main power to the Weld Station 2 When the switch is in the 0 or OFF position the main power to the unit is disconnected 2 When in the 1 or ON position main power is reaching the unit and it can be started 22 Under normal operating conditions the unit will not start when the green START push button is depressed if the disconnect is in the 0 or OFF position 22 This switch also provides a means to lock out the switch using a sm
36. 30161 866 665 1829 BLOWER ROTATI ON If blower rotation is incorrect the unit will suffer a significant performance loss as well as an increase in noise level Make sure the blower is rotating properly To check blower rotation have a colleague start the unit count to 4 and then stop unit As the fan slows watch the rotation When power is properly connected the blower will rotate counter clockwise when viewed from the exhaust of the Weld Station unit Make sure to check rotation from the exhaust top side To change the blower rotation direction simply swap any 2 of the incoming power leads PLEASE NOTE IT IS VERY IMPORTANT TO VIEW THE ROTATION FROM THE EXHAUST OF THE WELD STATION Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 STARTUP PROCEDURES The Weld Station power must first be turned on by rotating the Power Disconnect Emergency Shut Off switch to the ON position The unit can then be started by simply depressing the green RUN button The blower will start immediately but may take a minute or two to reach full speed The automatic pulse cleaning system will automatically turn on in the automatic mode SHUTDOWN PROCEDURES Proper Weld Station shutdown is one of the key factors to achieving maximum filter cartridge life To properly shutdown the Weld Station LEAF simply turn the three way mode sw
37. 5 Long The 19 long pieces are placed above and below the opening These will cover all 3 bolt holes above the opening and all 3 bolt holes below the opening cd The 25 long pieces are placed on the sides of the opening These gasket pieces will be between the upper and lower gasket pieces and will cover the 2 bolt holes on each side of the opening 22 The 4 gasket pieces must be placed centered over the bolt pattern 2 Once all four flat gasket pieces are placed there should be no gap between the gaskets 2 Once all four flat gasket pieces are placed then punch a hole into the gasket at each bolt hole to allow a bolt to pass through Be careful not to damage the gasket Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 27 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 INSTALLING THE FLAT GASKET ON THE COVER PLATES Flat Gasket must be places around the outside of all the cover plates before assembly onto the unit 2 The flat gasket must be cut to length from the roll For each opening the following pieces should be cut 2 19 long and 2 25 Long cd The 19 long pieces are placed along the top and bottom short sides of the cover plate These will cover all 3 bolt holes above the opening and all 3 bolt holes below the opening cd The 25
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39. HE MAIN UNIT UPRIGHT WITH LIFTING Toon 24 MOVING THE ENNO MN 26 INSTALLING THE FLAT GASKET ON THE UNIT see see poe Be Ge Ee Ge ee Ge ee Se Ge Ge s NE RR De SG EN ee P Dy Se ee ERG ee Ge GE N Ge ee EG ENEE ES 27 INSTALLING THE FLAT GASKET ON THE COVER PLATES ee ese ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee 28 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 A 29 ATTACHING THE SECONDARY BO Merknad Ge ee Ee oe REV 30 REMOVING THE INTERNAL PANEL BALES 32 INSTALLING THE INTERNAL PANEL BAFFLES orina 33 INSTALLING THE INTAKE SPARK BAFFLES ese ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee 34 REMOVING THE TABLE SLIDES inician se tota es de se see sd oe ee de ed nr ee ee ed ENEE Ne Se se N ee ES we Ge ie vanene we ee ge we ee RENE RRE se NE 36 INSTALLING THE TABLE SLIDES AND TABLES ees ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee 37 INSTALEING THE LEVER HANDLES ee 39 INSTALLING THE OPTIONAL DUST TRAYS ini 40 HENTET 42 AIR AND ELECTRICAL CONNECTION DIAGRAMS ccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccceccccccs 43 COMPRESSED AIR CONNECTION NN
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44. agnostic issues as well as the maintenance and service issues while in the field The wire numbers will be shown in small Black numbers at each end of the wire The wires are be numbered by the node meaning that several wires connecting into one point will have the same number Labels are placed on the terminal blocks as well as the wires Starting in December of 2009 Clean Air America switched over to LED lighting to reduce operating costs and provide a greener system A Weld Station may be equipped with one or two lights for each booth A second light may be added after the Weld Station has been installed for additional lighting Your Clean Air America sales representative can help in arranging this addition Wiring for Remote Start Stop buttons Remote Safety buttons and the Economizer are shown on the wiring diagram Multiple electrical options accessories are available for the Weld Station If an electrical option has been added then see the Weld Station Users Manual for additional information NOTE
45. all padlock thus preventing accidental power up 2 This is an interlocking disconnect meaning the door to the electrical box will not open if the switch is in the ON position When dial is in 0 position all main power to the unitis OFF 1 position the unit is powered up and ready for operation the unit is ON CAUTION Prior to performing maintenance always use a meter to confirm the power source is locked out Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 MODE SELECTOR SWITCH ed This switch controls the mode of the unit 22 The Auto position sets the Weld Station in Automatic mode and allows the economizer to function 22 The 0 position stops the Weld Station operation 22 The Man position sets the Weld Station into Manual Override mode and allows and runs the motor without any effects of the economizer or sleep function The optional remote mode switch can be installed to control operation of the mode from a second location The unit can be started or stopped from the secondary location but a hierarchy for modes is used The stop function always has highest priority the manual mode second and automatic last See the wiring diagram for wiring of the remote mode switch installation 2 The Clean Air Economizer switch can be installed to control operation of the Weld Station based o
46. as G SM F9ezie Of OvADSF B Z esed E HS 40 dHE Assy xog Eas E 99005 S 9c sA gue L s uec TAN Or Paws un sco reoo v I Oc uu ugL eweA oc00iv z BL dens JOIAJ 5 x1 salas Ov6 SM sse Z 8 jueauupjeAA JaploH Jor Jasa sauac gyog SAA eene E A Iquiessv JONESY sanag amxc SAN OSLLE LEI DU se suog emoa 9z00zd I Sr eum Jamola Szoda L vr os XN gom 5 Lozoly t 365 194 GO UISZ Zi map veel ebpuned vevd 100003 v 6 Up 1000 end Salas 999 SM ste L 8 JUSLUP IAAA junopy JOON Salas G SAA Salte E aleld J8 07 Xog Ind E Sevag OG GA SALLE 9 9 BIE J8 07 jueurieduio JOJON E salas gR SA eine t sS SJE d 1840 jusuniedulo AJEA Saa eec SA amp M Lt 1uaLuplaM SUE ISNEUX seusc GYG SA bolle LJ jusulpieM SPIIS algel sauas ORS SM lie F I ege wu wew e savas e Sw Soit L NOLLdIHOS3O ON Lavd ALO ON Wall r F G 9 fi 8 Tr i Taak TU SE 2S Es TREER EWE ERG IG EE A EE RATE T E T rer T at vs 3 140 i 133HE s 38d pr amp EBFBOLOE ZLARNWEN MOON USD Wid SR DIE LL Amnunp ACHEN SUDD lesu QUE 20 XX UT i V AN Edda A HAR THOU L HOU dH TDI rao INGUST b A Sort pio ujoeg LE 800 E 1908 Assy M 133 MIE 01 0 0 LE AG ae 9 1011 uum MOE OM YN GIr com www clean Clean Air America Inc Innovation in Air Filtrat
47. ct the performance of the unit by reducing air flow Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 REMOVING THE INTAKE SPARK BAFFLES The spark baffles must be removed for installation and cleaning 1 First carefully slide the Reverse Flow spark baffle upward into the top channel 2 Then pull the bottom of the Reverse Flow spark baffle out 3 Next pull the top of the Reverse Flow spark baffle out of the channel 4 Repeat steps 1 through 3 for the other Reverse Flow spark baffle as well as both metal mesh spark baffles Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 71 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 CLEANING THE INTAKE AREA 22 First remove the intake spark baffles The intake cavity contains the internal spark baffles as well as the internal T shaped wire track When cleaning make sure to work around these obstacles to remove as much debris as possible z Initially it is recommended to check this area every 3 months or as often as the intake spark baffles need cleaning However make sure to clean the intake area when significant amounts of debris begin to accumulate The intake area can be cleaned with a small hand broom and dust pan o
48. d from the work area This data will be used to predict the time to change the filters or adjust the preset levels Remember no two applications are exactly alike Because of this your own experience will be needed to optimize filtration and minimize filter replacement costs Cd Once you have verified that the Weld Station is picking up the fumes or smoke look at the metal intake spark baffles at the back of the welding booth s These filters should be washed when they become visibly dirty contaminated cd fthe unit begins auto pulsing at 7 0 in H20 and the smoke is still being drawn in at an acceptable level the setting could be increased to a higher number The correct number is based on trial and error 22 The process for determining your specific filter change interval is based on many variables Please feel free to establish a filter change interval that meets you application and desired performance results By properly monitoring the filters you will reduce filter costs and improve the efficiency of the units 2 Proper filter cartridge replacement is important to optimal performance of the Weld Stations Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 What determines the maximum acceptable pressure differential reading 2 The answer is a reading slightly less than the point where the unit stops drawing in an acceptable level of smok
49. dge filter and bolt on access panels allow access to the motor compartment and valve compartment for maintenance Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 FEATURES AND SPECIFICATIONS GENERAL FEATURES e e e e e e e e 9 9 S S 9 S S Patented Down Flow Air Cleaning Technology Filter Element Design 12 75 OD x 26 Long Flame Retardant 100 Cellulose 4 Filters for a total area of 904 sq ft Silencing Built in Acoustical Lining Heavy Steel Construction and Powder Coat Paint Finish Pulse Air Reservoir 2 1 Valves 1 Compressed Air Connection 1 0 f Valve Pulse at 70 90 psi Clean Air AutoPulse Controller A Programmable Pulse Controller with Filter Differential Readout Manual Mode Options Motor Contactor and Overload On Off Push Button with Center Light Disconnect Switch 2 24 x 24 x 2 Metal Mesh spark baffles and 2 24 x 24 x 2 Reverse Flow spark baffles for each unit and each booth Customizable Filters 61 dB Noise level on OSHA scale with clean filters 73 dB Noise level on OSHA scale with dirty filters Soft Starting to avoid initial amperage spikes Pressure tracking to maximize airflow for filter loading Economizer for automatic start and stopping of the motor blower based on demand Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superio
50. e the energy of sparks Because these bafflers and filters are the first in line concerning air flow they become soiled by welding smoke and need to be cleaned periodically How often they need to be cleaned is dependent upon the amount and type of welding performed Feedback from welding instructors which we greatly value indicates that many welding labs clean them every six to twelvemonths cd Itis recommends that educational facilities inspect the baffles every quarter or every 3 months and clean them as needed cd tis recommended that the baffles can be washed with a garden hose or if carefully used a pressure washer Be sure they are dry before placing them back into the Weld Station 2 Many welding instructors assert the easiest and most convenient way to clean the baffles is by first simply shaking the loose debris from the baffles and then spraying them with a compressed air hose Whatever method you prefer it is IMPORTANT that the baffles be cleaned periodically cd fthe baffles are not cleaned they can affect the performance of the Weld Station restricting of air flow and reducing the performance quality 2 Examine the metal mesh filters at the inlet of the unit These filters should be washed when they become visibly dirty contaminated 22 How often they need to be cleaned is dependent upon the amount of welding performed and the given application fthey are not cleaned they can affe
51. e 60 MANUAE MODE COUNT ZZ u u ed UTEM 61 MANUAL MODE VI IT u uuu E 61 OPTION MODE SHUTDOWN PES u uu uuu uu uuu uuu u u uu uu Ee Ge Go oe ei AEAEE ee ee ie ed 61 OPTION MODE SHUIDWN DELP E n 61 OPTION MODE RUN PLS DELP uu u uu u ee di de oe se oe ed ee ie ee ee ee ee ea ee Ge ender EN Re Re ie Ee ee Se ee ie 62 OPTION MODE ALARM DELP ees a des 62 OPTION MODE SLEEP TIME sn 62 OPTION DEFAULTS uuu EE OE EE OE ORE EEN 63 BLOWER ROTATION WEE 64 STARTUP PROCEDURES ccccccecccecccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccecceccccccccccccccccccccccccsccceccs 65 SHUTDOWN PROCEDURES E 65 MAINTENANCE ssassssssssassasassassassassassasassasassssssssssassasasssssssasssssasassssssssssssass 66 CATCH BA IBI NERIS NN 66 DTM NE 68 CLEANING THE INTAKE SPARK BAFFLES ci ne ae GR ae Ee ee ee Pe ed De 70 REMOVING THE INTAKE SPARK BAFFLES ooie ees eie ee ii ee Gie Ge GE aa 71 CLEANING THE INTAKE AREA een 72 CARTRIDGE FILTER MAINTENANCE EEN 73 He 73 Filter MAN A e Ge Ge Ee Ge oe GR ee ee Ge Ge ee Ge Ge Ge Ge GE GR EG GE ee EE Ge GE Ee GE 73 NEON 74 How to Determine the Filter Change Interval ee AR Ee ee ee RE ee ee ee ee ee ee 74 What determines the maximum acceptable pressure differential reading
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53. e plume 22 Ifthe unit still draws acceptably at 7 0 in H2O then the controller can be set to begin the auto pulse cycle at a higher level Please see the controller programming instructions for this procedure cd fthe unit stops draws acceptably at 5 0 in H2O then the controller can be set to begin the auto pulse cycle at a lower level Please see the controller programming instructions for this procedure Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 How to replace filters NOTE It is important to ensure that the filter gaskets seal correctly for proper operation of the Weld Station This will ensure that you do not get particulate past the filter compartment The easy filter clamping system of the Weld Station helps with faster filter replacement and maintenance 1 Press the red STOP button and allow blower to spin down This may take several minutes 2 Rotate the Disconnect Switch Emergency Stop Switch to the 0 or OFF position This S will disconnect power to the unit to prevent R WeldStation J the unit from being started during the filter CLEAN AIR ERICA INC change Please follow all lock out tag out procedures 3 Shut off the compressed air supply to the Weld Station 4 Open the filter door by simply removing the lever handles handles Make sure to retain the bearing washers so that the
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55. ear and unclog evenly During pulsing the number of the valve which is being pulsed will flash on the lower line of the display for 0 2 seconds while the valve is being pulsed Motor status is indicated below the Mode Display This displays the contact status for activating and holding in the motor contactor When the controller is running an indicator icon will be displayed This indicator resembles a pair of small rotating triangles Additionally input and output contacts can be checked by holding down the ESC key The display will change to show the appropriate input and output contacts Once power to the system is turned on the controller will start up in Automatic Mode Several Manual and Option modes are available as well which are shown below 2 The controller will always restart into automatic mode when power is cycled regardless of the mode before the power was shut off To change modes hold the B button while pressing the or Button Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 Auto MODE This mode is set up to automatically control the pulsing depending upon how much dirt is entrenched upon the filters This is determined by a differential pressure sensor measuring the pressure loss across the cartridge filters This mode is automatically active when entering the mode The controller will pulse when the
56. ect Incoming Power Incoming Power Size A Wire Se Cable SO 3 a1 pe 29 5 135 152 20 230V Three Phase Motor Size Motor FLA Unit FLA Disconnect Incoming Power Incoming Power e HP Size A Wire Ga Cable SO Setti ak 460V Three Phase Motor Size Motor FLA Unit FLA Disconnect incoming Power Incoming Power e uu Size A Cable eto ti ak 3 an Las wa 5 62 70 20 Rn Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 CONNECTING THE SECONDARY BOOTH LIGHT S Ed On the main unit the light s are already prewired into the Weld Station electrical panel and ready to go 22 After determining the configuration of the Secondary Booth back to back or side by side the light for the Secondary Booth must be connected to the unit f you examine the bottom of the intake there are 4 oblong cover plates These plates allow access to a T shaped wire track 2 Inside the wire track for the main unit is a 2 conductor pin connector The main unit has a female connector with female pins 22 Inside the wire track for the secondary booth is a 2 conductor pin connector The secondary booth has a male connector with male pins Both connectors will be located behind the right side cover plate For the main unit this is located beneath the electrical panel
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58. ge the counter press the OK button The number of cycles will begin to flash Use the and buttons to increase and decrease the amount of cycles respectively Press the OK button again to set the counter value OPTION MODE SHUTDWN DELP Shut Down Pulse Limit This option sets the pressure differential at which the shut pulse down sequence will be activated in Automatic Mode see Auto Mode Above This pulsing state is referred to as the offline cleaning cycle To change the value press the OK button The number of pressure value will begin to flash Use the and buttons to increase and decrease the amount of cycles respectively Press the OK button again to set the counter value Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 OPTION MODE Run PLS DELP Run Pulse Limit This option sets the pressure differential at which the running pulse sequence will be activated in Automatic Mode see Auto Mode Above This pulsing state is referred to as the online cleaning cycle To change the value press the OK button The number of pressure value will begin to flash Use the and buttons to increase and decrease the amount of cycles respectively Press the OK button again to set the counter value OPTION MODE ALARM DELP Alarm Limit This option sets the pres
59. h of the lever handles 22 Place the threaded stud of the lever handles through the holes in the filter door arms Ed Screw the lock nut onto the back of the lever handle This will keep the lever handle attached to the door during maintenance and prevent the loss of hardware WeldStation CZ Screw the lever handle into the weld nut and wi tighten the door down A AIR MERICA INC Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 39 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 INSTALLING THE OPTIONAL Dusr TRAYS NOTE Dust trays are an optional add on and are not necessary for most WeldStation operations If purchased there are two dust trays for each A main unit These dust trays must be placed in the CLEAN AIR filler compartment As the self cleaning cycle is SRICA INC activated dust will be blown from the filters and accumulate in the dust tray See the Maintenance section for proper servicing of the dust trays 2 Remove the lever handles holding the filter door shut Make sure to keep the 3 8 flat washers See the Installing the Lever Handles section if necessary 2 Swing the filter door open to allow access to the filter compartment Slide the first dust tray under the front two filter rings which support the front two filters
60. he main unit for a side by side configuration 22 The secondary booths can be placed to the back of the main unit for a back to back configuration Weights of the assemblies vary based on configuration options and application set up Please see the Unit Weight section for more information The electrical and compressed air connections are located at the top of the unit Please see the Air and Electrical Connections Diagram section for more information ES F en j a Fi ka I amp i KA t E F e Fj Fi E T ie ef Skvavsd3 VIN WOUL ax rb e IT KN TET l SL icy a Ea TOI DKG tel Tera es INS i SA Lis Idd kis geren 50 ADD Anpren ap bw 1595011 0102 teuer open ug i V N Ad All pages rani 325 ny tti 4 j HD HE eus E alias G ues FEM gt d VIN e Assy D ahve n E ho a A 8 ke Ka Lad i Ta jns ai F CHE E E LI 133 maia p Yid L 1 maj asDud JHE elBuis uonDIs PIM dHE S OOLIE Eon pe Gest Od TE GL Tiy gj a 304i SN www clean air com 706 291 1700 866 665 1829 00 0 292 88 6ll Cal S6 vro tS Srle PRS MYA TD Clean Air America Inc 7 Superior Drive Rome GA 30161 GLE S6 S601 i ZE Lv Ot 6701 y E x I E S E S 3 O c C ws e i E F Ke n li t F 3 4 I I I I D no xxx n 140 0 Lusaug add hd zEerz 0102 soone
61. he pressure differential readings displayed on the controller lt may be easier to raise the plastic flip lid cover to access the display The controller will allow the pressure differential to build to 3 0 in H20 inches of water column This means the unit will automatically pulse the next time unit is stopped This value may be different if the options on the controller have been changed The controller will allow the pressure differential to build to 7 0 in H20 At this point it will automatically pulse while the unit is running until the pressure drops below 7 0 in H2O This value may be different if the options on the controller have been changed Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 When the unit begins pulsing it does not mean that the filters are no longer unusable This pulsing is simply the cleaning cycle which extends the filter life and reduces operating costs Your actual controller settings will be determined by your experience and set up Over time the filters will clog to a point where the pulsing will not reduce the pressure differential to an acceptable level This is the point when the filters should be changed cd The base line reading is a reference point of the reading with clean filters Initially you should take readings on a weekly basis or at any point where the smoke plume is visibly not being remove
62. hree months to a year 2 To check and empty the dust trays simply open the filter door This is done by unscrewing the lever handles Make sure to retain the bearing washers 2 Swing the filter door open 2 In the bottom of the of the filter compartment are the dust trays They sit below the filters and below the filter door The dust trays are yellow 2 Lift the right dust tray up by the handle until it hits the filter ring underneath the filter 22 Pull the dust tray towards you out from under the filter ring Set the dust tray aside Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 2 Slide the left dust tray to the right so that it is below the filter door opening cd Lift the left dust tray up by the handle until it hits the filter ring underneath the filter 2 Pull the dust tray towards you out from under the filter ring Set the dust tray aside 22 Empty both dust trays and then reinstall them They are identical and can be placed in either position 22 For directions on replacing the dust trays see the Installing the Dust section Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 CLEANING THE INTAKE SPARK BAFFLES The Reverse Flow spark baffles and metal mesh spark baffles are designed for inhibit and reduc
63. ide of the unit 22 For most installations it will be necessary to remove the internal baffle plates to install the cover plates ATTACHING THE SECONDARY BOOTH The Weld Station main unit can have a e WeldStation secondary welding booth attached for added welding stations This booth can be attached to either side or onto the back of the booth This achieved by connection through the rectangular opening with bolt patterns on the sides and back of the unit intake plenum The secondary booth will have a matching openings with bolt patterns in the intake plenum NOTE Before connecting the main unit and secondary booth the Flat Gasket must be installed around the connection opening 22 Remove the table slides from the WeldStation adjoining booth walls The same bolt CLEAM AIR is used for mounting both table AMERICA INC FT in Welding Smoke Remove slides to the common booth walls 22 For easy access to the bolt holes remove the internal spark baffles lt Do not install of the metal mesh spark baffles and Reverse Flow spark baffles until after the unit and booth have been joined together fthe spark baffles are already Weld Station User Manual March 2011 Copyright Clean Air America Inc Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 Page 30 of 114 Innovation in Air Filtration C
64. ing Clean Air America has standardized on Wye or Star voltage wiring method Wiring O 2 m2 O ia EE 21 connections in the motor s pecker head must be made using the screw terminals of the distribution block The distribution block ip ololoololalo PEN A D must be screwed to the inside of the pecker head 2 DN DR 6 21 22 23 U E E 7 Ty 34 die d S 9 All wires and air tubing leaving the electrical box should be bound together and prevented from laying lose on the cabinet floor LL The wires must be routed out of the electrical box and attached to the floor of the cabinet using the wire routing tracks The ME E EN E WO A L L cables should then turn up the first valve and route under the reservoir to the second valve The motor cable is attached to the conduit and then through the 3 4 strain relief Wires should be tight but not stressed EE DN 10 The high voltage wires from the disconnect to the VFD and from the VFD to the motor must be routed behind the VFD NOT OD o as drawn to isolate the high voltage from the low voltage wires included with pod ae 11 Once attached the door must open fully at least 90 degrees with out interference The door is also removable for eased OL maintenance pod e 12 Main power for the lights is drawn from the electrical box to a main junction box in the valve compartment The lights for the dd m M l main uni
65. ing inserted into the same height on Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 37 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com ANM AIR 7 Superior Drive 706 291 1700 A INC Rome GA 30161 866 665 1829 both sides of the booth so that the tables is not tilted Once the table has been installed it can be moved by simply pulling the table out and sliding it into another height channel The table can also be left partially extended from the booth to allow welding of larger objects outside the booth When doing so make sure the welding does not exceed range of the airflow for the booth Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 INSTALLING THE LEVER HANDLES n od e For each main unit there are two lever handles These n handles must be installed in the filter compartment door for ad ING increased ease of maintenance Fi feld Smoke Romer clean air com 22 Remove the bolts holding the filter door shut The P 706 291 1700 door was bolted shut during shipping to prevent damage to the lever handles Make sure to keep the 3 8 flat washers however the 3 8 retaining bolts can be discarded The filter door may swing open allowing access to the filter compartment 2 Swing the filter door closed Place a 3 8 zinc flat washer on eac
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67. itch to O After approximately 1 minute the Weld Station will begin to cycle through its offline cleaning process If the default settings are being used this will take about 3 to 4 minutes However if the default settings are not being used this off line cleaning cycle could take upwards of 10 minutes Always wait for the cleaning process to finish before disengaging the Power Disconnect Emergency Shut Off switch 2 The Weld Station can be shutdown easily by turning the mode switch to O The blower will not stop immediately and may take several minutes to fully stop The automatic cleaning system will continue to operate once the mode switch is changed AND the blower has stopped This is normal and desirable the off line cleaning is the most efficient cleaning method 2 Do NOT use the Power Disconnect Emergency Shut Off switch to deactivate the unit unless it is an emergency situation NOTE Do NOT shut down the Weld Station by disengaging the Power Disconnect Emergency Shut Off unless it is an emergency situation If the Weld Station is shut down in this manner it will NOT perform offline cleaning and will diminish the life of the filter cartridges Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 MAI NTENANCE CATCH BASIN MAINTENANCE NOTE Dust trays are an optional accessory and are not necessary for most operations If
68. lean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 installed remove them See the Removing the Spark Baffles section of the user manual 2 Place the main unit in the final location This may require bolting on some of the cover plates before placement due to obstructions If risers are being used they must be installed on the unit before final placement 22 Place the secondary booth next to the main unit This may require bolting on some of the cover plates before placement due to obstructions If risers are being used they must be installed on the booth before final placement 22 Slide the secondary booth into place and align the plenum openings and bolt hole patterns 2 Each rectangular opening has a ten hole bolt pattern Fasten the secondary booth to the main unit using 10 1 4 20 x 1 0 black Socket head cap screw 20 black 1 4 flat washers 10 black 1 4 lock washers and 10 black 1 4 20 nuts Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 31 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 REMOVING THE INTERNAL PANEL BAFFLES The internal spark baffles must be removed for some Weld Station installations Internal baffles are located in both the main unit and secondary booth 1 Begin by loosening and removing
69. ligned with the bolt pattern on the baffle supports 6 Fasten the baffle to the supports inside the plenum area using 6 1 4 20 x 0 75 zinc plated hex head bolts 6 1 4 zinc plated flat washers and 6 1 4 zinc plated lock washers 7 Repeat steps 1 through 6 with any other baffles Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 33 of 114 Clean Air America Inc 7 Superior Drive Rome GA 30161 INSTALLING THE INTAKE SPARK BAFFLES All of the intake spark baffles must be installed before using the Weld Station These baffles are the first defense in stopping sparks from passing into the weld station Smaller width secondary booths will only have one spark baffle of each type The metal mesh spark baffles must be installed behind the Reverse Flow spark baffles 1 First carefully slide the top of the metal mesh spark baffle upward into the top channel of the intake at a slight angle approximately 10 degrees 2 Then push the bottom of the metal mesh spark baffle inward so that the baffle is vertical and aligned with the bottom channel of the intake 3 Next slide the metal mesh spark baffle down into the bottom channel of the intake 4 Slide the metal mesh filter all the way to the right hand side of the intake Make sure it is seated in the bottom of the channel and shifted so that it is flush with the side of the intake 5 Repeat steps 1 through 4
70. ling Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 INSTALLING THE TABLE SLIDES AND TABLES Once the unit and secondary booth are attached together the table slides and welding tables can be installed into both the secondary booth and the main unit Place the table slide on the wall of the unit so that the slide channels are horizontal and the channels open to the inside of the booth Ed Align the bolt hole pattern on the table slide to the bolt hole pattern on the side wall of the booth Cd Fasten the table slide to the wall of the booth using 4 1 4 20 x 1 0 black socket head cap screws 8 black 1 4 flat washers 4 black 1 4 lock washers and 4 black 1 4 20 nuts The screw heads should be on the outside of the booth When a secondary booth is being attached on the side of a main unit 2 table slides are being attached to a common booth wall In this situation each of the 4 bolts must be used to attach both table slides If the table slide is being installed on the common wall between a main unit and secondary booth the bolt head can be on either side 22 Once all the table slides have been attached to the booth walls insert the table into the channel at the desired height The table simply slides into the channels of the table slides on both sides of the booth Make sure the table is be
71. lled in the bottom of the electrical box for each economizer lead Next 18 2 m e 1 I sd SOOW cable is run as shown in Details G There is no polarity on the economizer NM 2 2 16 When adding a Remote Manual Override Switch a hole must be drilled in the bottom of the electrical box Next conduit must 20 2 be run in the field to the desired location The jumper from 34 to 36 must be removed sere SO 7 JM 17 When adding a Remote Safety Relay a hole must be drilled in the bottom of the electrical box Next 18 4 SOOW cable must 3 be run from the electrical box to the remote safety relay push buttons The jumper from 50 to 51 must be removed o o 3 18 SOOW cable and THHN wires are rated for 600V All 480V wires are isolated from other wires by 30mm Wires for the TO L1 L2 L3 pressure sensor are isolated from all wires carrying voltage higher than 24VDC by at least 30mm additionally the sensor circuit sn P amp Y KE is protected using a 3A breaker O OOO 3 p 19 Breakers are active when showing red and tripped or deactivated when showing green DE Ee r to n 20 Use the following chart to determine breaker type 40 O 33 me 3 Breaker Location QTY Type Size Voltage O o B1 Terminal Strip Trans Primary 2 UL489 3A 600VAC o 35 g B2 Terminal Strip Trans Secondary 1 ULA89 3A 600VAC 38 36 O B3 Terminal Strip Lighting Circuit 1 UL489 3A 600VAC O 37 2 B4 Terminal Strip Pressure Se
72. n welding Multiple Economizers can be wired in parallel The unit can be started from either location however the unit can only be manually stopped by pressing switching the mode to 0 The unit will stop automatically based on the Economizer timer See the wiring diagram for wiring of the economizer mode switch installation Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 INTERLOCK ACTIVATE 22 The safety circuit is set up so that the drive will not activate without the internal interlock being activated The Interlock Activate button releases drive interlock and allows the drive to operate The interlock resets on power loss and must be reactivated when power is reconnected z Interlock status is displayed on the controller display INTERLOCK DEACTIVATE 22 The safety circuit is set up so that the drive will not activate without the internal interlock being activated The Interlock Deactivate button releases the interlock and keeps the drive from operating z Interlock status is displayed on the controller display Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 LIGHT SWITCH 22 The light switch is a maintain single push button 22 Simply depress the white button and the lights will turn on The button will stay mostly depre
73. nals are used to connect to the transformer The green contacts are grounding terminal blocks and must connect to 65 e of unit 3 The transformer uses IP 2X finger safe protection guards The electrical box has a keyed cam latch and lift off hinge to secure Clean Wd 34 EMT the door The transformer is a class 2 transformer and the disconnect emergency shut off is rated as a motor breaking switch Compression Bb gt Air Connector 4 Primary branch circuit protection consisting of an inverse time fixed trip circuit breaker rated at 3OkA IC trip must be provided 4 2 a 1 2 1 2 a 3 4 by the end user A WS 5 must be attached to a breaker properly sized for the equipment A single weld station unit must not be 3 8 3 8 attached to a breaker greater than 250 of the FLA of the motor according to NEC Code The breaker should be rated at 125 I of the unit FLA rounded up to the next standard breaker size ha di I ds 5 Clear flexible tubing is run from the pressure sensor to the air fittings All air lines must be run free of kinks E 1 c sl 6 The disconnect emergency shut off device is rated at 20 Amps Additional disconnecting means must be rated at least 20A 27 28 29 es SS SIE A A 7 The DIN connectors on the valves must seal with the SOOW cord using the grommet provided with the connector r T 7 2 2 11 12 O L1 L2 Io l OR Se E 24VDC O 5 6 212223 O E EN EN O 8 See Details D and E for motor wir
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75. nit This can be done by sweeping the dust into the dust trays The dust trays can then be serviced as normal Alternatively excess dust in the Weld Station User Manual March 2011 Copyright Clean Air America Inc Innovation in Air Filtration ean Air America Inc www clean air com 706 291 1700 866 665 1829 Page 78 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 filter compartment can also be removed through the suction of a proper vacuum system 15 Remove the covering from the first filter duct 16 Place the new filter onto the filter ring with the gasket seal end down The end with no sealing gasket must be up Make sure the filter is properly seated 17 Replace one of the filter caps onto the top of the filter The sealing gasket on the cap must be down and the nipple on the cap must be up There are 4 tabs on the outside of the cap which must point downward to capture the top of the filter 18 Tighten the filter cartridge with the filter clamping mechanism To avoid the air leakage make sure that the round sealing gaskets on both the filter and the filter cap are compressed at least by 0 25 by tightening T handle at the top of the filter cartridge This is done by rotating the metal T handle counter clockwise when viewed from below Do not over compress the gaskets 19 Repeat steps 15 through
76. nnections are defined in Electrical Connections and Compressed Air Connections sections of this manual 2 During installation always be careful The Weld Station is a top heavy unit and may require experienced personal to move and set up Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 WELD STATION DESCRIPTION DISCLAMER The Clean Air America Weld Station is designed to accumulate smoke residue particles and other by products of the manufacturing process The nature of these accumulations may be flammable Operating the Weld Station with these materials could result in a fire inside the unit The Weld Station is not recommended for use with highly combustible materials or explosive materials or particles The Clean Air America Weld Station consists of 2 Weld Station Housing Motor Blower System 22 Four Cartridge Filters A OER INC at in Welding smoke Removal 2 Online Automatic Pulse Filter Cleaning System 4 866 665 1829 y v The dirty air inlet is located inside the booth at the E back of the booth portion Metal Mesh spark baffles and Reverse Flow spark baffles protect the inlet The clean air outlet is located on the top of the unit above the motor access panel The optional silencers or exhaust deflectors may be installed on the outlet end A large opening door provides easy access to the internal cartri
77. nsor 1 UL489 3A 600VAC O O 47 3 3 3 O 44 Oo O E 25 44 O E 5 S Man lt I 45 c 45 og ne 25 NOl Nol nole gt O O 4 E 41214 8 l l l dp M O gt x 21 All wires are 16ga THHN stranded wire EXCEPT 22 Use the following chart to identify the VFD bw Q O 49 9 App a Motor cables is 12 4 SOOW cable mic Of b Valve leads are 16 3 SOOW cable Incoming Power Part Number 9 50 C x C Wires between the disconnect and contactor are 5HP 460VAC 3 Phase 132F0026 Ou 51 Se Ol 12ga wires from SOOW cable or THHN 3HP 460VAC 3 Phase 132F0022 ez Nn s 3 5 d Light cables are 18 2 SOOW 5HP 230VAC 3 Phase 132F0016 T vo e me es e Kavlico Sensor and the voltage regulator wires 3HP 230VAC 3 Phase 132F0014 EE one 77 SE f Incoming power wiring is run by customer and 5HP 208VAC 3 Phase 132F0016 DO must be rated at 600V 3HP 208VAC 3 Phase 132F0014 52 Breaker B2 EU MUN x ae 3 Breaker B3 3 9 Break r B4 O _ E o 30 Oo O O 2 Controller Color Sample List O 3 Wire Number Index PHASE 1 O Black e _e O 0 Ground 30 Pressure Sensor Signal White e PHASE 2 53 aa 83 1 110VAC Supply 31 Motor Start Signal Gray e e elo Ose 2 110VAC Supply 32 VFD Running Signal Yellow e a PHASE 3 edo 7 580 Q 3 24VDC Supply 33 Light Power Wire i To MAN 4 NO ei Je 38 Dirty Air 4 24VDC Supply 34 Remote Stop Jumper so Ms Mad Ee uu To Econ 1 Gnd mr 5 480VAC Phase 1 Switched 35 Off
78. ntain the blower speed and eliminates much of the power required at the unit start up Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 REDUCED MAINTENANCE The Weld Station LEAF uses the Variable Frequency Drive VFD to manage the motor s operating speed This in turn controls the airflow inside the unit and allows for more efficient operation through the Pressure Tracking feature This reduces the impaction of dust upon the filters inside the unit and allows The reduced impaction means the dust can be cleaned easier and every cleaning cycle is more efficient This feature can increase the life of the filter by up to 10096 which reduces maintenance time and costs REDUCED NOISE Noise is created inside a unit by moving parts such as the blower wheel and moving fluids such as the air through the unit With the Weld Station LEAF the air flow is managed through the blower control By managing the airflow the noise due to moving parts and moving air is reduced Measurements have shown that the noise level with clean filters can be dropped from 74 dB to 61 dB This is a reduction of more than half the noise Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 SYSTEM CONTROLLER Clean Air America Weld Station are controlled by a Clean Air AutoPulse Contr
79. ntroller input 18 Breaker B4 e rO To Main 4 pue qu terminal block 4 To VFD input 53 Junction Box Detail A Unit Light 1 2 5 VDC Voltage Regulator Electrical Electrical Box Body Box Body To Controller input 18 O I Dirty Air Dwyer MS 331 a Differential Pressure Sensor HIGH VOLTAGE 9 Clean Air Differential Pressure Detail D High Voltage NOTE Remove Jumper O 33 Motor Wiring Dirty Air 150 451 Sensor Economizer SS Detail G Economizer Field Wiring Detail I Remote Safety Push Button Detail J Dwyer Pressure Sensor Wiring Detail K Remote Safety Relay Term Strip Wiring Detail M Kavlico Pressure Sensor Wiring THE INFORMATION CONTAINED IN DESCRIPTION Schematic Number WS5 L3 THIS DOCUMENT IS THE SOLE PROPERTY OF CLEAN AIR AMERICA Weld Station Flexi booth CAP Ture WC 4 Full Electrical System VFD No HMI No FSS INC AND MUST BE RETURNED UPON REQUEST ANY REPRODUCTION oF FILENAME Conduit Fitting EE EE TT J T THIS DOCUMENT IN
80. o not attempt to operate the equipment without electrically grounding the panel The connection to the earth ground must be proper and provide a low impedance path to the earth to prevent hazardous voltages from appearing on equipment Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 MOVING THE WELD STATION MAIN UNIT There are various ways to move the Weld Station main unit c fthe Weld Station unit has NOT been uncrated or is still on the pallet then it can easily be moved by using a fork lift truck Place the forks under the pallet s main beams and simply lift the unit Keep in mind the motor end top of the unit is heavier and forks may need to be shifted toward the motor end Cd fthe Weld Station unit has been uncrated then it can easily be moved by using a fork lift truck Attach the lifting chains or cables to the fork head ache bar Attach the other end of the lifting chains or cables to the lifting lugs The top of the unit can then be lifted using the fork lift truck Place a wooden 2 x 4 underneath the raised end of the unit This wood piece will create a gap allowing the forks to be slid under the unit make sure not to scratch or damage the unit Cd fthe Weld Station unit is uncrated and upright then the unit can still be moved with a fork lift truck Place the forks under the unit portion of the main Weld S
81. ods include attaching a chain hoist or come along or both to the eyelets provided at the top of the unit 2 When the unit is being lifted the bottom of the unit may shift If possible brace the bottom of the unit to prevent slipping C A 2x4 brace is fastened to the front floor flanges of the booth This is used during shipment to prevent the collapse of the booth side walls This 2 x 4 should be kept in place while bringing the unit upright to prevent damage 2 SLOWLY hoist the unit up supporting it whenever and wherever possible Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 22 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com AM AIR 7 Superior Drive 706 291 1700 A INC Rome GA 30161 866 665 1829 2 DO NOT let the unit slam suddenly when bringing the unit into the upright position This can cause damage to the unit cd f risers are being used then attach the risers before bringing the unit upright See the Weld Station Accessories user manual for additional instructions z Please proceed cautiously N MI Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 BRINGING THE MAIN UNIT UPRIGHT WITH LIFTING TOOL NOTE Please be sure the chain hoist come along or chain cable is rated for that amount of weight to be lifted Se
82. oller This controller manages the cleaning cycles of the filters motor start stop controls the Clean Air Economizer and some of the LEAF feature controls Not all options are present on every machine Programming Mode Port Interlock g zn Inactive LII I 1 vill xl BEG VFD l Valve 1 Running Activation LUE Pressure Valve 2 ES Differential Activation e A Overload Tripped A Buttom OK Button Controller Running A Button B Button Button ESC Button Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 FILTER CLEANING CONTROLS The Clean Air AutoPulse Controller has been implemented on all Clean Air America Weld Stations as a filter cleaning controller The controller is connected to a differential pressure sensor which measures the pressure drop across the filters This pressure drop is displayed in the lower right of the front display on the controller The controller can be manipulated using the buttons below the front display The Pulse time on the valves is set internally and cannot be changed The valves will open and pulse for 0 2 seconds There is a 20 second delay between the valve pulses The valves will pulse in sequence alternating between the two valves until the all the pulsing cycles are finished The controller is set to pulse a full cycle so that all filters w
83. ork Lift Truck 1 32 Allen Wrench 2 15 Box Head Wrenches A gt d Jee mu ai ae me E d ge 5 am ma pe ds AY P a e i ZA x ke ch 4 E k T e f b y a le uM E eria r e Y keeft Fa E A Ur Lal eem j 1 he h RK li ai e cy e ie Geh l i is Z E 1 Utility Knife 1 Set of Ratchet Straps s n 1 Small Flat Head Screwdriver EE for Electrical Connections Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 Optional Recommended Tools 1 Air Ratchet 1 32 Allen Bit 1 16 Socket Bit 1 Ziel Drive Socket 1 Flashlight Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 1 Set of Fork Extensions 1 Fork Lifting Tool Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 SINGLE UNIT PARTS LIST The following parts are shipped with each Weld Station Single no secondary booth Colors of some parts may very if a custom color was ordered Please confirm that all parts have been shipped before 30 1 4 Black Flat Washers 30 1 4 Black Lock Washers beginning assembly 30 1 4 20 x 1 0 black socket head cap screw 42 1 4 Black Nuts 3 Locking Hole Plugs icta arrive in 50 rolls 2
84. ormation aIir corm www clean Clean Air America Inc C A LL i ST C O ur S gt O C lt M 706 291 1700 ior Drive 7 Super A K F 5 9 H N LIO AAHS dd id GELE DIE L Amnupr Ee EN MOER as 15750511 0102 so onuor pen quoc el VIN id VIN sil dade BH E EU XX o Es ad SM HE of E senos s USOS P M dHEEOOLIE WIN Assy oker lend TS 00 OE mes Y ena ISDUA e JHE lBulc UO Pr dried dd t 1 asDud dHE SBUIS UOYDIS PIOM 1 dH 9 0011 LN Me Vi v ua VM LO d M v O m H onsejd WEG ejqejsnipy 196 z X 9 8 PVEHJEAST GOOLW z 3E O d MODE us HE PIMA 83095 G SM seat b ZE OT JeURUON UIT X UlpZ x upg apeg eds usa MIN 210014 Z St PELI UIT X Ug Xx up opgi ydg MOS 523 10014 2 SG FIG Pied ura ECH RSC Use LGN r Paes ull scoisoiv L w UOT ener do Z te E SHE Z Z LUPE J pIDH soiniasaH t 55195 gycs SM tse E te quiussw IOIAGSTH SOUSG OTG SA o TERT o aar re sae ET ted 9i ETE ESEL WIN TTC TN neg 1 004 i Zi sd ER dr Kion DEn 1 9i reg Eege Tee JEE y amp JUSLUP BAA epueu sa UMNO POH JEW 97592005 gy guOBEISPEEM Jeep st poel Assy deg 18413 Qo UGL zi LOL LE If et SIE EIER ZL UPON HOG Mi sS OSS went L i w SUPER NS ENE sees SSM avant L Gi d Held AOD xog I
85. ors This eliminates starting amperage spikes as well as inertial effects of the blower In non VFD systems these spikes can be as high as eight times the full load amps PRESSURE TRACKING The Variable Frequency Drive VFD inside the control panel allows the Weld Station to track the usage of the filters This allows the unit to automatically increase the speed of the motor to compensate for the additional air restrictions caused from dirty filters This features is an automatic feature and cannot be disabled This feature alone can save 55 of the energy costs over the life of the filters ECONOMIZER M EIN when the unit is in automatic The economizer is a standard feature on the Weld Station LEA mode the economizer will start the unit automatically when the user begins welding When the user has stopped welding the unit will shut the unit down automatically One minute after the end of the welding arc unit will go into Sleep mode If the user begins welding within that one minute time frame the timer will be reset and recommence when the welding ends again SLEEP FUNCTION The sleep function can be set as described in the Option Mode The sleep function is set to last 5 minutes by default When the one minute Economizer timer ends sleep mode is activated During this time the VFD ramps down the speed of the motor to about 2096 of the maximum speed During this time the drive uses only 296 of the energy but is able to mai
86. penses Without adequate lubrication pneumatic components can run sluggishly and inefficiently be prone to air leakage Water in the supply line must be removed using a dryer or water drain trap SHUT OFF VALVE Each unit must be fitted with a shut off valve capable of being locked out with blow off capability Safety procedures such as lock out tag out procedures must be followed with pneumatic as well as electrical systems This means the valve must be a 2 way valve which will exhaust the air from the Weldstation when the shut off valve has been locked out The exhaust port should be fitted with a pneumatic muffler to reduce noise if above unacceptable levels Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 ELECTRI CAL CONNECTI ONS Clean Air America Weld Stations can be set up to operate on various power sources Please see the following electrical chart based on the specified power To ensure proper operation a certified Clean Air America Inc installer or professional electrician should perform power connections Any damage incurred from improper electrical power connection will void the warranty of the Weld Station The incoming power is connected to the unit at the conduit connection located on the top of the unit in front of the exhaust panel For convenience and quick connection there is a 3 4 Weather tight female EMT fitting The
87. pressed air inlet supply is a 1 NPT male fitting Use a regulator to adjust the pressure to 70 to 90 PSI A dryer may be needed to condition the air before entering the Weld Station 1 0 f Valve Pulse at 70 90 psi WW SN N 5 8 Minimum compressed air supply line required 1 Recommended NOTE Do not operate the Weld Station for an extended period of time without an appropriate compressed air supply Doing so will greatly diminish the life of the filter cartridges AIR REGULATOR The compressed air for the Weldstation must be regulated at 70 to 90 PSI A Regulator is used to allow the high pressure air supply lines or tanks to be reduced to safe and usable pressure for pulsing the unit If the pressure is too low the valves may not properly clean the filters If the pressure is too high it may damage the valves AIR FILTER The compressed air for the Weldstation must be clean Dirty air entering the system can cause damage to pneumatic components The air should be filtered to remove all contaminants by the compressed air supply system prior to entering the Weldstation Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 DRY AIR The air supply to the weld station must be dry or drained Water carried with air into the Weldstation can wash away lubricating oil This can mean excessive wear to pneumatic components and higher maintenance ex
88. pressing the B Button Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 MANUAL MODE COUNT This mode will pulse the valves one at a time in sequence until for a set number of cycles The counter denotes the number of cycles To change the counter press the OK button The number of cycles will begin to flash Use the and buttons to increase and decrease the amount of cycles respectively Press the OK button again to set the counter value Press the A button to begin pulsing The pulsing can stopped by pressing the B Button When the controller begins pulsing a new line will appear on the controller above the counter set line This indicates what cycle the controller is on MANUAL MODE VTEST This mode will pulse the desired valves one at a time upon command The front panel displays what valve will be activated To change the valve press the or buttons to increase or decrease the valve number respectively Press the A button to pulse the selected valve one time There is no delay using this method however each pulse is still only 0 2 seconds OPTION MODE SHUTDOWN PLs Shut Down Pulse Cycles This option sets the number of pulses performed during the shutdown sequence in Automatic Mode see Auto Mode Above This pulsing state is referred to as the offline cleaning cycle To chan
89. r Drive 706 291 1700 Rome GA 30161 866 665 1829 2 Sleep Mode to reduce energy usage and maintain blower rotation during intermittent operations 22 Managed blower and airflow speed for reduced dust impaction and better cleaning cycles BLOWER MOTOR SPECIFICATIONS 22 Backward Incline Air Foil High Efficiency Plug type Blower s Single Phase 115 208 or 230 Volts 2 3 Phase 208 230 or 460 Volts 2 3450RPM Z2 3600 RPM NEMA MG 1 230 460 V 60 3 std UNIT WEIGHT The weight of the Weld Station unit can vary depending on the configuration application and accessories purchased This is due to the wide selection of motors blowers filters and accessories Clean Air America has to offer Please see the following chart for approximate weights TT oe Weld Station Secondary Booth 3 Wide 350 lbs to 400 lbs Weld Station Secondary Booth 4 Wide 400 lbs to 500 lbs Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 INSTALLATION The Weld Station requires some minor assembly 2 A standard unit will come with an exhaust cover pre installed The unit and a booth are integrated into a single machine referred to as the main unit 2 A secondary booth can be attached to the main unit and creating a Dual Weld Station If no secondary booth is used then the main unit is referred to as a Single Weld Station 22 See the Weld Sta
90. r an appropriate vacuum system Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 CARTRIDGE FiLTER MAINTENANCE Filter Features Filter Design 1834 Filter Dimensions 12 75 OD x 26 Long 100 Cellulose 22 Resin by Weight Pleat Construction Flame Retardant HQ V SS WW WM 4 Filters for a total area of 904 sq ft 226 sq ft per filter Standard Operating Temperature up to 220 F Short Time Exposure up to 300 F Mullen burst rated at 25 psig S WWW Other Filters are available depending on the application Filter Maintenance Filters are of excellent construction and of the best quality available The filters are preconditioned with a unique process which has proven to be effective over time with long filter life and excellent cleaning characteristics The cellulose media is even able to withstand and recover from water immersion due to the filter s high resin content 2296 by weight and mechanical resilience It is important to keep the filters clean and replaced on the proper interval for the proper operation of the Weld Station The point when the filters must be changed depends upon the specific application Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 Welding and grinding frequency the type of particulate that is
91. r sopen guyone bw 155501 1 OL0Z So LEE iopsen weg V N VIN ge MDISUI y ez a mur ap e EP AN CIS ig HARI E ast Liv FECI kim anita SYMA leide ry d Cure LUCIE DA VIN t Zeen yy NS av a ins Op anas V iMi rl IUe 0 l sm sDud due SIDUS 9 UOHDIS PIOM dH 9 001 1 O d EH MI ONS GOL j di MB 3 PIT META RO NONE T nd 1xa ds AHO tenen ifla SE 7 OO cS 706 291 1700 866 665 1829 SC Ly SZ ZV0l www clean air com OO Ot 294 88 61 I G6 rroe v8 Ed I FS GH LE Clean Air America Inc 7 Superior Drive Rome GA 30161 EI Sep eegen x C lv Of 6701 ra E x I E S E S 3 O c C ws E O C G 9 8 s ENE fo eras nos o repara WE LL Lad YES m MN VN ad aal Es ap dag OFL V dE BEN SEE rea PEN S one VIN Sd icon Assy mou one sot S lt 3 N NE 14614 uo ujoog HE jong SALAS G UONDIS PIOM 8 1011 _ lge I x S s As d LAW es E di uas v 01 Or L6 07 LV sal tw G S wawa A O mm DO 6 LL see ST lv D ES SZ VOI im gt 599L cm 8 9761 do 000 oo lt c C92 AOE c sz 2600 VS St LE Sm o QU S SU SJ mm Q ev y EG NE Sog 519 et Q cot Sv c6 OQ s E oc Co c ZE Lv Sep OF r01 S S601 e rv v9 r 19 Orc HUN UIDUI SUI JO YOO ayy
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93. ssed 22 Depress the white button again and the lights will turn off Cd This one light switch operates the all of the lights on both the main unit and secondary booth BREAKERS Z Multiple breakers are located in the electrical box 2 Breakers showing GREEN are safe or tripped and will not allow current through the breaker 2 Breakers showing RED are bot and will allow current through the breaker Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 KEY LATCH The key latch is a cam style latch that rotates clockwise to unlock the electrical box and counter clockwise to lock the electrical box 22 Simply insert the key into the key hole and press down firmly while the key is rotated When closing the electrical box the gasket will need to be compressed This may require additional force in closing the electrical box 2 Keep in mind the electrical box also has an interlocking disconnect emergency shut off switch If this switch is not deactivated the door will not open even if the key latch is unlocked Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 WELD STATI ON LEAF FEATURES SOFT START The of a Variable Frequency Drive VFD allows the motor ramp up to speed rather than across the line starting contact
94. sure differential at which the filter cleaning alarm will be activated in Automatic Mode see Auto Mode Above To change the value press the OK button The number of pressure value will begin to flash Use the and buttons to increase and decrease the amount of cycles respectively Press the OK button again to set the counter value OPTION MODE SLEEP TIME Sleep Time This option sets the length of time for the sleep function of the Economizer To change the value press the OK button The number of pressure value will begin to flash Use the and buttons to increase and decrease the amount of cycles respectively Press the OK button again to set the counter value Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 OPTION DEFAULTS The Weld Station will arrive preprogrammed with no necessary adjustments needed The Option Modes allow for the changing of some variables which may extend filter life or increase performance on non standard applications If the settings are changed the defaults are as follows 2 Option Mode ShutDown Pls tt 05 Option Mode Shutdwn delP 3 0 Option Mode Run Pls delP 7 0 Option Mode Alarm delP 9 9 22 Option Mode Sleep Time 05 Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA
95. t are connected directly to the terminal strip inside this junction box A similar junction box is located on the top of secondary booths Power for the lights in the secondary booth is run from the junction boxes back though the conduit and wire tracks to the main light distribution box and connected to the terminal strip Electrical connection for the secondary booth to the S main booth is done using the quick connects shown in Detail C These connectors are located inside the wire track beneath the intake C 2 Ey 13 WIKA and Dwyer sensors are wired and operate identically If a Kavlico sensor is used a voltage regulator is used to drop the 24VDC down to 5VDC If a Dwyer sensor is used see Detail J no voltage regulator is needed If Dwyer sensor is used an additional mounting hole must be drilled See Detail M for wiring of the Kavlico sensor Variable Frequency Drive VFD 14 The following labels must be applied 2 Ground Symbol labels applied to the box next to the grounding terminal blocks 1 E A Danger High Voltage Disconnect power before servicing label applied to the outside of the electrical door next to the disconnect 1 Laminated Electrical Diagram applied to the inside of the electrical door 1 NEMA 12 label applied to the See Note 11 up N inside of the electrical box O lt a EE S 1 1 ES 15 When adding an economizer a hole must be dri
96. tation unit Card board or rubber padding can be placed on the forks to prevent scratching of the unit Make sure the forks are on both side of the light s cables to prevent damaging the lights Do NOT place the Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 20 of 114 Innovation in Air Filtration Clean Air America Inc www clean air com AM AIR 7 Superior Drive 706 291 1700 A INC Rome GA 30161 866 665 1829 forks under the lights Do NOT let the forks enter the intake at the back of the booth area The Weld Station unit is top heavy and must be prevented from falling backwards during movement It is recommend that the top of the unit is bound to the mast of the fork lift truck during movement This can be done by wrapping a strap around the unit and mast Another method is to attach a chain or cable between the mast and the lifting lugs Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 BRINGING THE MAIN UNIT UPRIGHT No LIFTING TOOL NOTE Please be sure the chain hoist come along or chain cable is rated for that amount of weight to be lifted Ed Properly sized chain or cable can be attached to header bar on a fork lift truck The chain or cable can then be connected to the lifting lugs of the unit The forklift truck can then be used to lift and move the unit 2 Other meth
97. tion Accessories User Manual for accessory assembly instructions GENERAL INSTALLATION GUIDELINES Clean Air America s Weld Station units are shipped via freight and generally arrive on a flat bed trailer The main units are partially crated on a pallet and are shipped laying on their sides The secondary booths are partially crates and shipped upright Use a fork lift truck driven by a qualified individual to remove the crate pallet from the truck Occasionally fork extensions are helpful 22 Once the Weld Station unit is inside the facility ready to be uncrated please proceed cautiously Banding straps and plastic wrap must be removed Weld Station units are heavy and tend to be top heavy The motor and the majority of the metal is located at the top of the unit Please see the Unit Weight section for proper weights 22 There are 4 steel plate eyelets vertical at the top of unit These are the lifting lugs 22 There are 9 floor mounting holes on the bottom flange of the unit Innovation in Air Filtration Clean Air America Inc www clean air com 7 Superior Drive 706 291 1700 Rome GA 30161 866 665 1829 TooLs NEEDED FOR INSTALLATION The Following tool lists are given as a general outline Additional tools may be used or substituted based on availability The required tool list is given as a bare minimum required to assembling a Weld Station Powered tools are recommended Required Tools 1 F
98. tional place all of wire track hole plugs into the sides and back of the unit c There is a T shaped wire track built into the bottom of the plenum Each end of the T had an exposed 1 1 2 circular opening Each side of the main unit and secondary booth has a circular opening The back of the main unit and secondary booth each have a circular opening Simply press the open side of the plug into the circular opening It will lock in place 22 t may be necessary to install the hole plugs before setting the units in the final location Obstructions such as walls or other Weld Stations my prevent or hinder access Weld Station User Manual March 2011 Copyright Clean Air America Inc Page 42 of 114 IOn ltrat e www clean air com Air F ion In e Clean Air America and G Q mt 7 Superior Drive 706 291 1700 866 665 1829 Rome GA 30161 AIR AND ELECTRI CAL CONNECTI ON DI AGRAMS UOYDWLIOfU1 IAOU LOS 101208 u01J99uu02 02142914 PUD UOUIIS MOHI2UUOI ALY passa4duio 241 98s asvajg num 241 8uyps2do asofag 2ppu 24D SUOTJIIUUOD 2824 fo y0q 1m JANS INDIA 100g amp anpuooos up 07 Aamod paaf ma pun pun 24 AOL SUOIIIUUOD JPUA21X2 quo IY AAD SUOYIIUUOD WUWU ISIY nun uipu ay fo do 241 UO UOIDIO 240 Ssu0122uuoo MY possa4duio pup 10911991 Ws __UO DSauu0s jy passaiduio uon2euuo DI I8 3 AA YY d AAA CM A W AA E il I e

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