Improving Lives through Clean Air

Transcription

1 Improving Lives through Clean Air

2 Clean air is our passion. For more than 25 years, RoboVent has been driven by a commitment to improving the health, safety and quality of life for manufacturing workers through better clean air solutions. That s why we never settle for good enough when it comes to our products. We are continually working to make our products safer, more reliable and more efficient, so you can focus on your core business and leave air quality to us. This spirit of innovation has earned us a leading position in the collection and filtration of weld fumes, manufacturing dusts and other airborne contaminants. In these pages, you ll find numerous examples of this innovation, from our space-saving Spire Dust Collector to the revolutionary Delta3 Spark Arrestance System. All of the products you will see featured here have been engineered for flexibility, ease of use, consistent performance and unsurpassed quality. We are proud to count among our loyal customers numerous Fortune 500 companies as well as hundreds of small businesses who count on us to help them find the most efficient and economical way to meet their clean air goals. Our success is driven by a simple principle: listen to the customer and understand their needs. We don t just sell equipment. We engineer solutions designed around your goals, applications, facility and budget, and backed by the RoboVent Guarantee. We make clean air easy.

3 The answers you re looking for are here. History of RoboVent Client Testimonials...6 VentMapping Engineering VentMapping Engineering Indoor Air Quality Case Studies Welding Solutions Hazards & Regulations Manual Welding Ambient Systems Manual Welding Hi-Vac Source Capture Manual Welding Source Capture Systems Robotic Welding Source Capture Systems Robotic Welding Resistance & Laser Welding...38 Robotic Welding Hi-Vac Source Capture...39 Welding Safety Equipment...40 Metal Cutting Solutions Hazards & Regulations Metal Cutting Plasma and Laser Cutting Oil Mist & Haze Solutions Hazards & Regulations Oil Mist Source Capture Systems Oil Mist Ambient Systems Other Dust Collection Dust and Fume Control General Ventilation Make-Up Air and Exhaust Systems...60 Exhaust Blowers High Volume Low Speed Fans...62 Fusion Series Dust and Fume Collectors Collector Overview All-In-One Complete Packaged Product...66 Vertical vs. Horizontal Filters...67 etell Intelligent Controls edrive Automatic VFD...70 Dynamic Pulse System...71 RoboVent Endurex RMO Cartridge Filters Delta Fire Prevention System...75 Deflagration System Equipment Configurations and Options RoboVent ICE Integrated Cooling Equipment...80 Maintenance, Filters & Equipment Upgrades ClientCare Maintenance Program Replacement Filters Equipment Upgrades

4 More Than 25 Years of Excellence The RoboVent story begins in 1989, when we first opened our doors as a local dust collector distributor. Since then, we ve grown to be an international leader in ventilation and filtration with offices throughout North America and now also in Europe. We re honored to have many of the world s most successful manufacturing companies on our growing list of satisfied customers. We believe that the secret to success lies in one thing commitment to the customer. We constantly ask ourselves one simple question: What else can we do for our customers to make their businesses better? It is this drive for continuous improvement that fuels our quest for innovation in air quality system design. Over the years, we ve continually rolled out new and more advanced products and technologies to make our customers operations safer, healthier and more energy efficient. Through it all, our manufacturing customers have been a critical part of our growth. In 2014, the same year we celebrated our 25th anniversary, RoboVent was honored to be included in the Inc List of America s FastestGrowing Private Companies. We give the credit to our team s passion for solving customer problems a passion that continues to drive everyone at RoboVent today. Our Clients Some of the most innovative companies in the world have trusted their air quality to us. Our experience crosses a wide range of industries, including automotive, plastics, food and pharmaceuticals. Alcoa Aluminum Altec Industries Bobcat Caterpillar General Electric Gerdau Ameristeel Honda Hendrickson Trailer John Deere Our Affiliations Kiswel Weld Wire Kubota Lear Corporation Mercedes-Benz Rheem Stoughton Trailer Tenneco Automotive Toyota Volvo Planned Expansion Location. Service and Ongoing Support RoboVent 24-Hour Hotline: 888.ROBOVENT The RoboVent 24-hour hotline is available seven days a week. We understand your requirement for production and stand ready to help at any time. Maintenance Contracts Available Sophisticated air-filtration equipment represents a costly investment in your plant and the health of your employees. Proper maintenance is critical to the performance of that investment. RoboVent preventative maintenance programs provide the regularly scheduled expert maintenance needed to properly maintain your air-filtration and dustcollection systems, and greatly reduce the risk of unexpected system breakdowns and production delays. The Rock Solid RoboVent Guarantee. RoboVent systems are sized correctly for excellent filter life and effective smoke capture. This isn t always easy in a high demand business like dust collection. But, we promise every RoboVent customer will be satisfied. 4

5 Built for quality No matter what system you choose, you can rest assured that it will come with RoboVent s quality guarantee. We build safety, energy savings and efficiency into every piece of equipment we make. Our clean air solutions are designed for the needs of today s manufacturers. Lower operating costs: We re always looking for ways to reduce energy use, such as automated systems to ensure collectors run only when they need to. Additionally, our filters and equipment have been engineered to maximize filter life and reduce operating costs. One Supplier Single-Source Responsibility At RoboVent, we believe that personalized service is just as important as the product. That s why we take total project responsibility for the systems we deliver. Through a dedicated project team, we manage every step of a design-build project from concept through commissioning. Our value as a supplier-partner is best demonstrated through the successful delivery of hundreds of systems, many with demanding, fast-track schedules. We are your total-solution air filtration company. Superior safety and risk reduction: We have deep experience in controlling combustible dusts. Every piece of equipment we make is engineered to reduce the danger of fires or other problems that could put your workers and assets at risk. Easy maintenance: Longer-lasting filters are just the start. Our equipment is built to reduce the maintenance burden on your staff. With etell intelligent controls, you can move beyond preventative maintenance to truly predictive maintenance. We collect more dust with the RoboVent unit in a week than we did in a month with the competitor s unit. YOU YOU WORKING WITH WORKING WITH ROBOVENT R.B., Chief Maintenance Technician, Stryker OTHERS ROBOVENT.COM 888.ROBOVENT 5

6 Client Testimonials The plant air quality is much better, the morale of the employees has improved remarkably and we see an improvement in quality which is measurable by rework or a lack there of now, it s been a positive, plus all the way around. We ve had several suppliers, several customers come in that had been in here prior to the installation of the RoboVent system, and they are just like wow we can t believe the difference! D.T., Project Manager, Tru-Form Steel & Wire, Inc. From the very beginning (from design phase), we were looking at an exhaust system that was going to take care of multiple problems we were having. We started investigating, what was going to be the best method of removing the fumes from this line, we did a lot of research on different vendors and one of the leading names that always came up was RoboVent. The operators themselves are saying how much better the air quality is that they re working in. It s a lot cleaner air, and we see no haze whatsoever. R.H., Production & Welding Engineer, Futaba Corporation This project from inception, design, integration and completion went effortlessly despite uncooperative winter weather We chose your system for a number of reasons: quality, value, non-proprietary system design, efficiency of operation, and, bottom line, it gets the job done when others did not. D.H., Facilities Engineer, Gestamp Alabama, Inc. The smoke from our welding process created a haze which created the appearance of an unsafe working environment (there were) particulates in the air and film-buildup on our equipment. RoboVent not only cleared our facility of the haze and fire outbreaks, but raised employee expectations in terms of air quality. D.S. Maintenance Manager, Magna Corporation We have manufacturing facilities that are so clean and wellmaintained in terms of ventilation. Because there s no smoky air, it s much easier to keep the facilities clean. B.D., Senior Engineer, John Deere Company Looking back, I d say the ability to clean and re-circulate the air and save on utility costs was the biggest, and somewhat unexpected benefit of the new air filtration system. B.F., Welding Project Engineer, Lear Corp. Within the couple months that they were here they re very professional about communicating with me. They always made sure that they consulted with the right people - during the entire two months that they were here they didn t cause one delay in our production and everything kept running smoothly. I am very satisfied with what we have accomplished through RoboVent. Before it was always smoky now its crystal clear, we don t have as much dust accumulation on all of our tooling, which really cleans this place up. N.B. Manufacturing Engineer, Stoughton Trailers We had very much improved air quality, our cut conditions on our machines are better due to quality of air. The shop is cleaner and its obvious in the appearance of the shop and the product we re cutting. The product was shipped prior to our laser, we had no problems with the installation of the product and RoboVent came in and installed them in a timely manner and gave us lessons on how to operate the equipment. J.H., Operations Manager, WSM Industries 6 ROBOVENT.COM 888.ROBOVENT

7 VentMapping Engineering 7

8 VentMapping Engineering VentMapping Engineering Design Services Your facility is unique. To get the best results, your whole-plant ventilation system needs to be personalized to your individual environment. That requires a thorough understanding of your facility layout, fume-generating applications, airflow patterns and physical constraints. RoboVent VentMaping provides engineering and design services for custom solutions including fully ducted systems. VentMapping is a systematic engineering and design service that uses a holistic approach to optimize your air quality system. Our comprehensive approach helps us find the safest, most effective and most efficient way to meet your goals. Effective Dust and Fume Collection Starts with Data Collection Before: The airflow simulation shows the dirty air concentrating around equipment and the manufacturing process. After: A second simulation shows how optimal placement of dust collectors has effectively circulated and cleaned the air. 2.1 mg/m mg/m 3 8 ROBOVENT.COM 888.ROBOVENT

9 1. Onsite Consultation Each engagement starts with an onsite meeting to help us understand your goals and your facility. At this stage, we will review your fume-generating processes and the volume of fumes produced and work with you to establish specific and measurable air quality goals. We don t simply limit the discussion to meeting required regulations. We want to understand your current situation, your desired outcomes, and your unique challenges. 3. Modeling We use Computational Fluid Dynamics (CFD) to build an accurate model of the airflow patterns throughout your facility. Modeling and analyzing fume generation points, generation rates and airflow patterns allows us to predict the impact of different equipment configurations. Building your model may include: Facility CAD Model Creation CFD Analysis 2. Data Collection Next, we gather data about your current air quality. We use science-based methods to measure particulate levels throughout the facility so we can map how they are generated, how they propagate through the facility and where they end up. 4. System Design Using the simulation software, we can find the ideal placement and configuration for equipment so it works with, not against, your existing airflow and facility layout. This allows us to design a system that will give you maximum results with minimum cost and energy use. The unique aspect of the RoboVent system is that it is not just a venting hood it is an entire system that pulls the smoky air away from our operators. We strongly feel that this is the best solution for our employees. We are pleased to have accomplished this with the RoboVent system. And we are pleased to have found such a flexible partner in RoboVent a partner who works with us to help us achieve our goals. A.M., Senior Project Leader, Bobcat Doosan 5. Final Review and Analysis Once your system is installed and implemented, we ll make sure that the actual results match our predictions, and make any necessary final adjustments. ROBOVENT.COM 888.ROBOVENT 9

10 Indoor Air Quality 101 FILTRATION VS. EXHAUST Considerations in Selecting an Indoor Air Quality System When selecting an indoor air quality (IAQ) solution, you need to take a close look at your processes, facility characteristics and current air quality state. Evaluating these factors up front will help you choose between ambient and source capture. A few factors to look at: Your applications and processes: The character and volume of the fumes created depends on the processes you are using; processes such as cutting or grinding will produce larger dust particles, while thermal processes such as welding produce fumes made up of sub-micron particles. The volume of particulates: Continual processes will generate a higher volume over time than those that are sporadic. Robotic and laser welding applications create more fumes than manual welding. Cutting and grinding applications can generate large volumes of particulates in a short period of time. The health risks associated with your particulates: The health risks associated with your particulates depend on both their size and their chemical makeup. Weld fumes contain toxic elements and compounds such as manganese, hexavalent chromium, nickel, copper, vanadium, molybdenum, zinc and beryllium. Other types of dusts, such as those produced in the pharmaceutical, food, paper and construction industries, carry their own health and safety risks. Dust types with more serious health impacts will require more stringent control strategies. Airflow patterns: Dusts and weld fumes can travel far from their origin and impact workers who are not involved in welding or grinding applications. Every facility has its own unique airflow patterns, which influence how weld fumes propagate through the facility, where they end up and where they linger. The most effective and efficient air quality remedy will work with your airflow patterns, not against them. Facility layout and characteristics: Facility characteristics such as ceiling height, overhead cranes and the layout of your production lines will influence the way your air quality remedy is designed. Your facility and production line characteristics may dictate whether you choose a ceiling-mounted dust collector or a floor model, or whether hoods are a viable option to contain fumes for capture. Selecting the Right Approach What s the best way to clear the air in your facility? The right approach to indoor air quality (IAQ) depends on the applications you are using, the amount of dust or fumes generated, the specific health and safety risks of your particulate and the layout and characteristics of your facility. There are four basic approaches to indoor air quality for industrial facilities: Filtration vs. Exhaust The first choice you have to make is between a filtration system and an exhaust system. In an exhaust system, contaminated air is simply captured and exhausted outside of the facility. This is generally done using a ventilation system with large fans that pull dirty air out and exhaust it to the outside, often through the roof. A make-up air unit is required to return clean outdoor air to the facility and avoid creating negative air pressure inside the building. In a filtration system, dirty air is pulled into a collector and through a series of filters. The filters remove particulate from the air. Clean air can then be returned to the facility. A simple exhaust and make-up air ventilation system is the cheapest and easiest to install. If you only need ventilation to clear the air after occasional dirty work, this may be the right approach for you. However, if your industrial processes generate large amounts of dust and fumes on a regular and ongoing basis, filtration may be a better option. Filtration systems offer several advantages: Lower energy costs: While exhaust and make-up air systems push heated or cooled air out and replace it with outdoor-temperature air, filtration systems clean and recirculate air that is already at indoor temperatures. This significantly reduces heating and cooling costs. Environmental compliance: Blowing contaminated air into the environment may put your facility out of environmental compliance. The U.S. Environmental Protection Agency (EPA) is cracking down on outdoor emissions from industrial applications, as are other regulatory 10 ROBOVENT.COM 888.ROBOVENT

11 bodies in North America and Europe. If your processes produce emissions containing toxins such as manganese, beryllium or hexavalent chromium (all common byproducts of welding), or other pollutants of concern such as crystalline silica or carbon black, you need filtration to keep them out of your local environment and avoid potential fines. Cleaner rooftops: Blackened roofs often provide visible evidence of pollution around exhaust systems. Increasingly, community members and regulatory bodies are finding that evidence through photographs on Google Earth. Cleaner floors: What happens to pollutants that are exhausted to the outside? While some are carried away by the wind, many settle back down in the immediate vicinity. Some may even be pulled right back in through the make-up air unit. If you are exhausting a large volume of particulate, it will settle on cars in the parking lot and outdoor walkways, where employees will carry it home or back into the facility on shoes and clothing. For some types of dust, this may only present an annoyance. However, if your particulates are toxic, this can be a significant concern. Ambient vs. Source Capture The second major consideration is ambient vs. source capture. Ambient systems are centralized whole-facility solutions. They continually clean and turn over air from the entire building. Source capture systems are point solutions. They capture fumes and particulates at their source to prevent them from propagating throughout the facility. The choice between source capture and ambient filtration depends on the type and volume of fumes you are producing as well as the physical constraints in your building. If you are generating significant volumes of dangerous fumes, such as from robotic welding, in most cases it is preferable to capture them as close to the source as possible. Source capture reduces the amount of fumes that workers will breathe in both near the fume-generating process and throughout the facility as a whole. Hoods, fume arms, backdraft tables and fume guns collect dangerous fumes and particulate as they are created. However, source capture is not always possible. The size of parts being worked on and physical constraints such as overhead cranes may make source capture difficult to implement. In these cases, an ambient system combined with personal protective gear for workers closest to the fume-generating processes may be the best option. Ambient may also be a viable option for facilities that produce lower volumes of particulates throughout the facility rather than large volumes contained in specific areas. Many facilities use a combination of source capture and ambient systems. Depending on the system selected and the application it is used for, a correctly used source capture system will collect between 70-90% of fumes. This may have been enough in the past, but tightening air quality regulations and an increased awareness of health hazards are prompting many companies to add an ambient system to collect fumes and particulates that source capture may miss. A secondary ambient system can be especially helpful in the following situations: Welding large equipment that requires welders to move around the pieces they are welding. Relying on manually positioned fume arms while welding large parts. Utilizing open smoking bins where freshly welded parts are allowed to cool. ROBOVENT.COM 888.ROBOVENT 11

12 Improving Lives Through Clean Air At RoboVent, clean air is more than our business it s our passion. We measure our success in the number of manufacturing lives our systems have improved. As of now, that number is nearly 65,000 worldwide, and growing every day. Why does clean air matter so much to us? Because we understand the impact air quality has on the health, safety and quality of life for manufacturing workers. Better air quality means better health outcomes for workers, as well as improved productivity, lower turnover and better retention and recruiting results for manufacturers. That s why we provide education and resources to help plant managers and EHS professionals make informed, practical decisions about their air quality goals and options. The RoboVent Clean Air Initiative goes hand-inhand with our core mission to improve lives in the manufacturing industry. These stories highlight a few of the lives we have improved. For more, visit Plumbers & Pipefitters Local 495 Plumbers & Pipefitters Local 495 is a training facility designed to educate Union members in the skill and art of welding. Located in Cambridge, Ohio, the program hosts several classes per day in order to teach students the fundamentals of the welding process. There are 20 weld booths where students can master their craft. The ongoing welding requires a fume collection system to facilitate a safe training environment. An existing system, which utilized one stand-alone dust collector for every two weld booths, was noisy and inefficient and had become expensive to maintain. RoboVent replaced their inefficient stand-alone collectors with one centralized system that would connect 20 fume arms with ducts to one large collector located outside the facility. The new system is cleaner, quieter and has reduced filter replacement costs considerably. Lives Improved: 300 Futaba Indiana of America Futaba Indiana of America Corporation is an automotive parts supplier operating out of Vincennes, Indiana. A new project called for them to produce a special exhaust system, which would create new weld fume challenges. The new part required a highly technical welding process and was made of stainless steel, resulting in highly toxic fumes containing hexavalent chromium. Futaba wanted a backdraft solution for their manual welding stations. RoboVent calculated the airflow requirements and engineered and implemented the solution. The new system provided highly effective fume capture and filtration and incorporated advanced features designed to improve filter life, save energy and reduce fire risks. As a result, Futaba was approved as a supplier for the new part. Lives Improved: 758 Stoughton Trailers Located in Stoughton, Wisconsin, Stoughton Trailers manufactures tractor-trailers and other transportation equipment. They came to RoboVent to solve a problem with weld fumes and particulates in their primary fabrication facility. RoboVent engineers designed the solutions with VentMapping, an engineering service that uses computer modeling to identify specific airflow patterns and filtration requirements for each area of the factory. Through the use of fume guns, Vortex towers and air control curtains, specific spaces in the production environment were able to be quarantined, preventing dust and fumes from escaping to other parts of the facility. The RoboVent system drastically reduced fumes, dust and smoke within the manufacturing environment, providing workers with a brighter, cleaner facility that boasts better ventilation and less dust. Lives Improved: ROBOVENT.COM 888.ROBOVENT

13 Welding Solutions

14 Welding Dust & Fumes HAZARDS AND REGULATIONS Effective Clean Air Solutions for Weld Fume Hazards For generations, welding has been a core component in the manufacture of metallic parts and products. From traditional manual welding applications to newer laser and robotic methods, welding continues to be integral to many industries, from automotive parts to ships, tanks and turbines. Since 1985, RoboVent has been a trusted partner for manufacturers seeking to mitigate the harmful effects of weld fume exposure. RoboVent is a leader in clean air solutions for welding applications. Over the decades, we have led the industry in development of innovative solutions such as our space-saving Spire dust collector (with the smallest footprint in the industry), flexible Grid configuration (for fast reconfiguration of manufacturing lines), and powerful Vista360 (for ambient filtration without the ductwork). We re continuing to lead the way with new technologies to make weld fume collection safer, more effective and more energy efficient. When it comes to weld fume collection, nobody does it better than RoboVent. Application Types and Characteristics The characteristics of smoke and fumes generated by welding can vary widely from plant to plant. The toxicity and the total volume of fumes generated depend on three variables: Type of welding process Base metal and filler metals used Composition of the welding rod For most processes, 80-85% of the fumes generated actually come from the welding wire. Since these fumes are thermally generated, the resulting particulates are very small, ranging from 0.1 to 5 microns in diameter. For every 1,000 pounds (453.6 kg) of welding wire used, 10 to 20 pounds (4.54 to 9.07 kg) of particulate are generated. The exact characteristics of those particles will depend on the processes, base materials and consumables used. Welding processes can be broadly categorized as robotic or manual. Robotic welding applications (including laser welding, SCARA and arc welding) usually generate large volumes of weld fumes at a consistent rate. If not collected or vented, these fumes can travel far from the source, creating health and safety hazards throughout the facility. Robotic welding applications are usually conducted in a hood to contain the weld fumes and make them easier to collect. 14 Manual welding applications generate far fewer fumes overall, but can present more acute dangers to welders. Fumes must be kept out of the breathing zone to protect welders from toxic elements in the weld fumes. Manual welding almost always requires some form of source capture. There are a range of source capture solutions appropriate for different types of applications, including fume guns, fume arms, backdraft or sidedraft tables and portable extraction devices. Where source capture is not possible, personal protective equipment (PPE) must be provided. If the facility has a large number of welders, additional ambient filtration or ventilation may be needed to maintain acceptable air quality throughout the plant.

15 Health and Safety Hazards of Weld Fumes Weld fumes can contain many toxic elements and compounds, including nickel, copper, vanadium, molybdenum, zinc and beryllium. Two of the most dangerous are hexavalent chromium (hex chrome) and manganese. Welding fumes have both immediate and long-term impacts on worker health. Acute effects of exposure to weld fumes can include shortness of breath and respiratory irritation; eye, nose or throat irritation; or nausea. In confined, unventilated spaces, build up of helium and carbon dioxide can lead to suffocation. Long-term effects of overexposure to weld fumes include cancer, kidney damage, emphysema and chronic nervous system effects, potentially leading to early disability or death. Overexposure can cause a serious condition called metal fume fever, or welding sickness, which causes non-specific, flu-like symptoms such as fever, chills, nausea, headache, muscle or joint pain, shortness of breath and fatigue. Acute cases can progress to shock or convulsions, requiring immediate medical attention. Chronic manganese exposure can also lead to manganese poisoning, commonly called manganism. Manganism causes neurological damage that can mimic diseases like multiple sclerosis (MS), amyotrophic lateral sclerosis (ALS) or Parkinson s disease. Overexposure to hex chrome can cause asthma, eye irritation and damage, and ear drum damage. It is also associated with elevated rates of several kinds of cancer. Meeting Regulations for Weld Fume Control OSHA takes three factors into account when regulating weld fumes: 1. Number of welders you have working in your plant. OSHA requires a minimum ventilation rate measured in cubic feet (or cubic meters) per minute per welder, unless respirators, hoods or booths approved by the U.S. Bureau of Mines have been provided. 2. Size of the space that houses the welder or welders. OSHA guideline mandates that any space with a ceiling under a certain height must have ventilation. 3. The type of metal that is being welded. Since most metals being used in fabrication are alloys, manufacturers must take into account every element that crosses the weld arc, not just the principal metal. Manufacturers must comply with permissible exposure levels (PELs) for total particulate exposure as well as exposure to specific toxic substances, such as manganese and hexavalent chromium. The OSHA 8-hour time weighted average TWA for weld fumes is 5 mg/m 3 ; OSHA PELs for specific toxic elements can be found on their website at Many world-class manufacturers are moving beyond OSHA PELs to follow recommendations from the American Conference of Governmental Industrial Hygienists (ACGIH). These voluntary, science-based standards are rapidly becoming recognized as international best practices. Effective Weld Fume Control System design for weld fumes must take several factors into account, including the type of welding conducted, the volume and toxicity of fumes produced, the level of exposure for workers, the physical characteristics of the facility and the airflow patterns within the building. For low volume manual welding, a backdraft table or portable fume arm may be all you need. Large facilities with high volumes of weld smoke may need hybrid systems that combine hoods or source capture with ambient filtration. An air quality engineer can help you find the best option. RoboVent has a wide range of solutions for weld fume extraction and control, including source capture, ambient filtration and ventilation options. We work with you to find an optimal solution that will maximize capture efficiency and minimize energy, filter and maintenance costs. ROBOVENT.COM 888.ROBOVENT 15

16 Manual Welding (AMBIENT SYSTEMS) Why Choose an Ambient Filtration System? Don t blow money out the roof! An ambient filtration system offers significant benefits compared to traditional ventilation exhaust and make-up air systems: Energy efficiency: Filtering and recycling factory air keeps heated or cooled air in and lowers overall energy and operating costs. Regulatory compliance: Ambient filtration does a better job of clearing contaminants from the air than traditional ventilation, resulting in higher employee comfort and better compliance with health, safety and environmental regulations. The Vista360 Push-Pull Configuration Vista360 creates circular air patterns in the facility that continually pull contaminated air into the filtration unit and push clean, filtered air back into the plant. Here, short lengths of duct are used to capture ambient air. The number and placement of Vista360 collectors are determined using our proprietary VentMapping Engineering Services. Hi-Vac Industrial Cleaning System The RoboVent Hi-Vac Industrial Cleaning System is a rugged centralized vacuum that can be attached directly to your dust collection system for easy collection bin clean out. The central vac system eliminates the need for ladders or scaffolding to clean out collection bins on ceiling-mounted dust collectors. Ambient Dust Collector The Vista360 and Spire360 are a ductless ambient air option that is easy to install, reconfigure and maintain. They are powerful ambient solutions made to capture fumes and dust from manual welding, metalworking and other industrial applications. eq monitors not shown to scale. eq Air Quality Monitoring System With the RoboVent eq Air Quality Monitoring System, your dust collection equipment is on when you need it, and off when you don t. eq continually monitors the air quality in your facility and automatically regulates your RoboVent system s airflow in response to particulate levels. Helpful Hint Vista360 can also be effectively used to create a circular airflow pattern similar to Vortex (see page 22) 16

17 VentMapping : Effective Dust and Fume Collection Starts with Data Collection Before: The airflow simulation shows the dirty air concentrating around equipment and the manufacturing process. RoboVent Hi-Vac Industrial Cleaning System Cleaning out overhead dust collectors just got a whole lot easier. The RoboVent Hi-Vac Industrial Cleaning System is a rugged centralized vacuum that can be permanently attached to your dust collectors for easy, automated clean out. The high-vacuum system collects particulates from all of your dust collectors into a centralized bin for easy disposal. It can also be configured as an industrial-strength central vac for general facility cleaning. Reduce dust collector maintenance time and costs Eliminate the need for ladders or scaffolding to clean out collection bins on ceiling-mounted dust collectors Reduce exposure to harmful particulates when cleaning out collectors or conducting general facility cleaning Can be used with Vista360, Fusion Series and Spire dust collectors After: A second simulation shows how optimal placement of dust collectors has effectively circulated and cleaned the air. ROBOVENT.COM 888.ROBOVENT 17

18 Manual Welding (AMBIENT SYSTEMS) Spire360 : Powerful ambient filtration with the smallest footprint in the industry. We make clean air easy. Looking for ambient filtration or displacement ventilation options for production welding or dust-producing applications? Spire360 may be the right system for you. Spire is a flexible, cost-effective alternative to centralized ducted systems for high-production industrial processes. Unlike standard displacement ventilation options, each Spire360 unit collects and filters ambient air and returns it to the facility. The unit is designed to collect contaminated air high on the unit and discharge clean, filtered at the bottom. Discharging air at the floor level creates a positive press zone of cleaner air which naturally forces dirtier air up into the filtration unit. Filtering the air in a facility avoids energy losses associated with venting heated or cooled air to the outside. Filtration is better for the environment, too, so you can ensure that you are meeting both health-and-safety and environmental regulations for air quality and emissions. Spire360 features: Small footprint: Our floor-saving design takes up about the same amount of space as a wire barrel. And since there is no ductwork to install, it s less intrusive and won t interfere with overhead cranes or production equipment. Energy Efficiency: Filtering and recycling factory air keeps heated or cooled air in and lowers overall energy and operating costs. Regulatory Compliance: Ambient filtration does a better job of clearing contaminants from the air than traditional ventilation, resulting in higher employee comfort and better compliance with health and safety regulations. Since contaminants are removed rather than simply blown out the facility, it will also ensure compliance with tightening emissions regulations and future Acceptable Point of Impingement Concentration limits. Easy Install: Spire360 is faster and easier to install than traditional ducted systems for displacement ventilation or ambient filtration. Since the Spire units have a very small footprint, it s easy to find space for them. Very Low Maintenance: Everything is easily accessible for fast filter changes and maintenance no special tools required. The single filter design makes filter change out fast and easy. And our proprietary etell system makes maintenance headache-free. Flexibility: Whenever you need to change your floor configuration, Spire360 is easy to move right along with your production equipment. 18 ROBOVENT.COM 888.ROBOVENT

19 etell Intelligent Controls Each Spire360 unit comes standard with etell, a revolutionary control system that learns your systems and routines, makes automatic adjustments to save energy and extend filter life and alerts you when maintenance is needed. See page 68 for details. Intake Plenum The intake plenum is located high on the unit to capture weld fumes carried upward by thermal currents. It pulls contaminated air into the filtration system where particulates are captured. Internal Hopper Dust is collected in easy-access dual internal hoppers. Just connect a standard shop vac to the 2-inch (50.8 mm) clean-out ports to remove the particulate from the internal hoppers. You could also connect these ports to a vacuum system for continuous removal of the dust. SafeSensor Particulate Monitoring SafeSensor is the Spire s advanced particulate-monitoring device that can detect leaks past the filters. If one should occur, SafeSensor will shut the equipment down and trigger an alarm. edrive Automatic VFD (option) The edrive constantly monitors airflow and automatically adjusts the motor RPM to compensate for filter loading. Energy peaks and valleys are evened out, and energy usage is cut by 20% to 30%, while filter life is extended by as much as 30%. See page 70 for details. Have sparks? Don t worry. RoboVent's groundbreaking Delta3 spark arrestor stops fires before they start. Spire360 can be equipped with the optional Delta3 Spark Arrester. Our groundbreaking technology that stops sparks before they have a chance to ignite. Delta3 can be added to the intake plenum to prevent sparks from entering the Spire360. You should consider adding Delta3 if you are engaged in spark-producing processes such as resistance welding, grinding or plasma cutting near the dust collector unit. Delta3 uses a unique, patented technology that outperforms competing spark arrestance systems eliminating 99.9% of sparks. Centrifugal action drives sparks and embers against the outer wall of the device, stripping off the thermal envelope that surrounds them so that they are rapidly cooled and extinguished. Delta3 delivers: Excellent spark control Self-cleaning operation Low pressure drop Spire360 Configuration Units are placed strategically on the factory floor to create air flow patterns for maximum capture efficiency. As thermal plumes of contaminated air rise, they are pulled into the intake plenums. Floor diffusers return clean air back to the facility. Particulates are captured by the filters and collected in an easily accessed internal hopper. That means no ducts to clean and zero emissions from the facility. ROBOVENT.COM 888.ROBOVENT 19

20 Manual Welding (AMBIENT SYSTEMS) Vista360 : Powerful Filtration in a Small Package Vista360 combines the advantages of a ducted push-pull system and a standalone collector in one small but powerful package. Each unit is built for durability, safety and easy maintenance, with rugged cabinet design and built-in features for fire safety and longer filter life. SafeSensor Particulate Monitoring SafeSensor is the Spire s advanced particulate-monitoring device that can detect leaks past the filters. If one should occur, SafeSensor will shut the equipment down and trigger an alarm. Dynamic Pulse System This patented system takes filter cleaning to an entirely new level. Far more than just a simple blast of compressed air, it has multiple valves working together in a computer-synchronized double-pulse sequence to virtually eliminate re-entrainment while propelling the dust down into the collection area. See page 71 for details. Endurex RMO Filters RoboVent s Endurex RMO filters use Reinforced Media Optimization and a rigorous quality control system to guarantee performance. In addition to RMO Technology a wide selection of media is available including high performance cellulose, NanoFiber and PTFE, so that the filters can be tailored specifically to the application. Internal Hopper Dust is collected in an easy-access internal hopper. Just hook up a central vac system or a standard shop vac to one of two 2-inch ( 5.1 cm) ports to clean out excess dust. Delta3 Spark Arrestor (option) Our proprietary Delta3 spark arrestance system uses centrifugal force to eliminate sparks at the source for superior fire safety. See page 74 for details. edrive Automatic VFD (option) The edrive constantly monitors airflow, and automatically adjusts the motor RPM to compensate for filter loading. Energy peaks and valleys are evened out, and energy usage is cut by 20% to 30% while filter life is extended by as much as 30%. See page 70 for details. 20 ROBOVENT.COM 888.ROBOVENT

21 RoboVent eq Air Quality Monitoring System The eq System will enable you to save a typical 50-55% reduction in energy. With the RoboVent eq Air Quality Monitoring System, your dust collection equipment is on when you need it, and off when you don t. eq continually monitors the air quality in your facility and automatically regulates your RoboVent system s airflow in response to particulate levels. eq works with the etell control system to modulate system performance in response to real-time conditions. eq also links with your dust collector s edrive system and regulates airflow, ramping the volume and speed up and down as necessary reducing energy costs, noise levels, and equipment wear and tear, and extending filter life. At the same time, air quality is always kept within defined limits to protect worker health, safety and morale. The perfect companion for any of RoboVent s ambient air quality systems, eq allows you to: etell Intelligent Controls Each Vista360 unit comes standard with etell, a revolutionary control system that learns your systems and routines, makes automatic adjustments to save energy and extend filter life and alerts you when maintenance is needed. Each unit has a wireless modem that connects to the Internet, so you can access information and have full control of your Spire units from anywhere using a free app on your iphone or Android device. See page 68 for details. Get real-time air quality alerts and control system parameters on a tablet or smart phone Monitor air quality levels over time and identify meaningful patterns with user-friendly reports Reduce energy use and maintenance costs for air quality equipment eq can be implemented on Vista360, Spire360, Vortex or PushPull Systems. The Vista360 Push-Pull Configuration Vista360 creates circular air patterns in the facility that continually pull contaminated air into the filtration unit and push clean, filtered air back into the plant. Here, short lengths of duct are used to capture ambient air. The number and placement of Vista360 collectors are determined using our proprietary VentMapping Engineering Services. ROBOVENT.COM 888.ROBOVENT 21

22 Manual Welding (AMBIENT SYSTEMS) RoboVent s Vortex Configuration The Vortex Configuration is based on a proprietary design that creates a circulating airflow to effectively capture and filter particulates in a plant. Cleaner air is then reintroduced to the plant in a seamless process. The system utilizes a unique mechanism consisting of eight to 12 nozzles that can be adjusted directionally to maximize the efficiency at which the air is cleaned. eq monitors not shown to scale. Typical Vortex Configuration: The system is engineered to create a plant-wide environmental vortex that turns the air at a consistent and steady rate. It is especially effective in cases where source capture of smoke or dust isn t possible due to large or unusual manufacturing operations, or when there are overhead cranes and limited ceiling space. The design of our Vortex Configuration is especially suited to the capture of dirty air in the most challenging places. Why the Vortex Configuration is an excellent choice: There are many benefits to installing a Vortex Configuration in your facility: It does not interfere with overhead cranes or other obstructions that cause trouble for other ventilation systems. No ductwork is required, which lowers installation cost and improves sight lines and visual appeal. It reduces collector noise levels by decreasing static pressure. 22

23 RoboVent s Push-Pull Configuration Clean Up Your Plant, While Allowing For Large Parts and Overhead Cranes Push-pull systems represent a total-plant solution that integrates a full complement of engineering, design and manufacturing capabilities available from RoboVent. When source capture isn t possible due to large parts or overhead cranes, the push-pull system can recirculate the air in the entire plant without conflicting with these obstructions. Typical Push-Pull System: Push-pull systems represent a total-plant solution that integrates a full complement of engineering, design and manufacturing capabilities available from RoboVent. Sometimes source capture isn t possible due to large custom parts and overhead cranes. A push-pull system is another effective ambient solution in addition to Vortex. Helping the Environment The days when dirty air was simply exhausted into the atmosphere with little thought to the consequences are long gone. In fact, the EPA has mandated new rules regarding the dispersal of these potentially dangerous fumes and smoke. In response, RoboVent has developed two powerful, total-plant solutions that best enable you to satisfy government regulations and create a safer environment. Furthermore, these systems filter and recirculate clean air to avoid the costly energy bills associated with replacing the warm air that many systems exhaust from a building. Environmentally responsible and cost-effective that s the RoboVent mandate. 23

24 Manual Welding (HI-VAC SOURCE CAPTURE) The RoboVent Extractor : Safe extraction of welding fumes at the source Welding fumes are a health hazard, and welders who inhale too many fumes run a higher risk of developing asthma, bronchitis, COPD and cardiovascular disorders. As a result, the U.S. and other international regulatory agencies are moving to more stringent thresholds for weld fume exposures. The American Conference of Governmental Industrial Hygienists (ACGIH) recommended limit for welding fumes in the workplace is 1 milligram of welding fumes per cubic meter of air (1 mg/m³), over the span of an 8-hour work day. Built for Better Performance and Control The welding gun has a conical suction head, welding tip and gas outlet for the shielding gas in order to promote good visibility and reachability of the object. The suction module is located at the end of the welding gun, close to the source of fumes. The shielding gas can be emitted with an increased flow velocity without raising shielding gas consumption. A ball-and-socket joint between the torch and hoses improves maneuverability. A conical suction hose, running from thin to wide. Where and how? The RoboVent Extractor is intended for use in MIG and GMAW welding processes that employ shielding gases. The gun will in all cases deliver an improved performance in comparison to current guns with source suction. 24 This norm is, in practice, exceeded in many workplaces. To comply, companies may adopt various measures including room ventilation, mobile extraction hoods or personal protective equipment such as dust masks or ventilated helmets. The effect of these is often insufficient: extraction hoods are not placed close enough to the source the objects to be welded are too large the welder is very mobile welding may take place in enclosed areas (e.g. the hold in a ship) personal protective gear is not used correctly In these cases, an integrated welding fume extraction provision in the welding gun is a more effective measure that is easier for the welder to apply independently in comparison to other means. The RoboVent Extractor consists of a welding gun with a built-in extraction module. The gun can be connected to a central extraction system or to a stand-alone version without any problems. One advantage of the RoboVent Extractor gun integrated with a RoboVent hi-vac collection system is that it can be used in different workplaces, such as in ships holds or tanks. ROBOVENT.COM 888.ROBOVENT The RoboVent Extractor reduces the welder s exposure to welding fumes by 90-95%.* EXHAUST SHIELDING GAS 2,000 1,800 1,600 1,400 1,200 1, Velocity (FT./MIN.) * This applies to (pulling) underhand welding. The reduction in (pushing) overhand welding and very swift horizontal movements may be slightly less.

25 Integrated Fume Extraction The RoboVent Extractor is a welding gun with integrated fume extraction. The gun can be connected to a central extraction system or to a stand-alone mobile extraction unit without any problems. The advantage of a mobile extraction unit with an integrated filtration system is that it can be used in different workplaces. Patent-Pending Faster Gas Flow Due to the design of the gas nozzle at the inside, the shielding gas comes out faster than normal. The combination of the faster gas flow with the correct extraction flow at the gas nozzle gives a perfect weld in all positions. Flexible and Maneuverable A ball-and-socket joint between the torch handle and the hoses offers flexibility and maneuverability. The RoboVent Extractor is a very light gun and weighs only 2.86 lbs. Due to the small size of the handle, the welder does not feel any difference between the Extractor and a standard welding gun. Helpful Hint The RoboVent Extractor prevents fume buildup when working in enclosed areas such as ship holds or storage tanks. ROBOVENT.COM 888.ROBOVENT 25

26 Manual Welding (HI-VAC SOURCE CAPTURE) FlexPro & ProCube : Hi-Vac Filtration Systems for Manual Welding Applications Our hi-vac filtration units collect weld smoke at the source. Choose from two great options: RoboVent FlexPro : The RoboVent FlexPro Hi-Vac dust collector is a versatile, simple and powerful solution for welding smoke extraction. Suitable for both manual and robotic welding applications, FlexPro is designed to cut costs and eliminate the need for overhead hoods. FlexPro provides powerful, centralized dust collection for multiple welders. And it s easy: simply attach your hi-vac suction tube, connect to a power source and start collecting weld fumes. RoboVent ProCube : When you need power, flexibility and mobility, look to the RoboVent ProCube. The ProCube puts highvacuum filtration power into a small, portable package that goes wherever you need it. At just 95 pounds (43.1 kg), 42 (106.1 cm) high and with a 24 x16.5 (60.7 cm x 16.5 cm) footprint, the ProCube is small enough to fit almost anywhere and light enough to move wherever it is needed. The optional wheels and handle make it easy for a single welder to move, making it the perfect choice for highmobility welding applications using fume guns. ProCube and Extractor : The Perfect Pair RoboVent ProCube is the perfect companion for the RoboVent Extractor Fume Gun. In fact, the two were made to go together. ProCube can be paired with one or two Extractor Fume Guns. Toggle between one-gun and two-gun use with the flick of a switch. The unit will automatically start when the torch is on, and stop when it is off, for easy operation and energy savings. The ProCube s size and portability make it an excellent choice for high-mobility applications such as shipbuilding or large infrastructure components. The 30 (9.14 m) reach of the Extractor hose gives welders exceptional mobility, and the ProCube can be easily moved along with the welder. Dashboard A simple, user-friendly dashboard lets you see performance and filter loading at a glance with a simple switch between single- and dual-gun extraction requirements. Delta3 Spark Arrestor Our proprietary built-in Delta3 spark arrestance system comes standard with every ProCube air filtration unit for superior fire safety. Delta3 uses centrifugal force to eliminate sparks at the source. See page 74 for details. Automatic Filter Cleaning System Filters are automatically cleaned using compressed air to minimize maintenance and extend filter life. edrive The edrive system constantly monitors airflow and automatically adjusts the motor RPM to compensate for filter loading, cutting energy use by 20% to 30% while extending filter life by as much as 30%. See page 70 for details. No-Spill Throw-Away Container Replaceable dust tubes with caps allow for clean, fast and hassle-free disposal of collected dust. 26

27 edrive Automatic VFD (option) The edrive constantly monitors airflow and automatically adjusts the motor RPM to compensate for filter loading. Energy peaks and valleys are evened out, and energy usage is cut by 20% to 30% while filter life is extended by as much as 30%. See page 70 for details. SafeSensor Particulate Monitoring SafeSensor is the FlexPro collector s advanced particulatemonitoring device that can detect leaks past the filters. If one should occur, SafeSensor will shut the equipment down and trigger an alarm. Dynamic Pulse System This patented system takes filter cleaning to an entirely new level. Far more than just a simple blast of compressed air, it has multiple valves working together in a computer-synchronized double-pulse sequence to virtually eliminate re-entrainment while propelling the dust down into the collection area. See page 71 for details. FlexPro ProCube Manual Welding Hi-Vac Applications: Ship building and repairs Tank building and repairs Large pipe welding Large weldments Applications that require extensive crane use Stainless steel welding Any application where a welder is overexposed to harmful welding fumes 27

28 Manual Welding (SOURCE CAPTURE) The RoboVent CrossFlow System The RoboVent CrossFlow System draws smoke away from a machine operator. This design ensures cost-effective removal of contaminants to help you meet federal regulations on emissions. The hood design is endorsed by the American Conference of Governmental Industrial Hygienists and is widely accepted as the correct way to address manualwelding ventilation. Virtually Eliminate the Risk of Fire. The CrossFlow System is designed to greatly reduce the risk of fires in the duct and filtration equipment using the RoboVent SparkOut System. For additional fire prevention, we also offer the RoboVent Supprex-200 Fire- Suppression System. Custom ducted CrossFlow workstation. RoboVent CrossFlow Table *welder not included. The RoboVent CrossFlow Table is a compact, self-contained air-cleaning system that recycles contaminated air using a high-efficiency, self-cleaning filter system. The unique CrossFlow design ensures clean air, a clean plant and the cost-effective removal of contaminants. The CrossFlow Table requires hardly any installation: Simply drop it in place and connect power and a compressed-air hose, and you are operational. The CrossFlow Table is a complete welding station that is ideal for educational facilities or repair shops looking for an all-in-one bench-and-filtration unit. RoboVent CrossFlow Table pulls smoke and exhaust away from the welder's line of sight The RoboVent CrossFlow Table comes with Side Plates to increase privacy and minimize weld flash disturbances. 28 ROBOVENT.COM 888.ROBOVENT

29 RoboVent FumeArms FumeArms are a versatile and simple solution for capturing smoke and fumes from welding and other industrial processes. Available in six-, eight- and 10- inch (15.2, 20.3, 25.4 cm) diameters, FumeArms are designed to move easily into position to extract smoke and contaminated air from a worker s breathing zone. Unlike many competing brands, RoboVent FumeArms are designed for industrial applications. They are durable, robust and virtually maintenance free. All joints are on the outside of the arm, not in the dirty airstream. All metal surfaces are powder coated to protect against scratches. RoboVent FumeArms are self-supporting, with smooth, low-friction control, and require minimal maintenance. RoboVent extension booms are designed to extend the reach of the RoboVent FumeArms, providing up to a 35-foot radius of combined coverage. The extension booms are heavy-duty, welded construction with a durable powder-coat finish. All booms include a bracket for securing the boom to a wall or post, and a heavy-duty flange to attach the FumeArm. Available in six-, eight- or 10-inch (15.2, 20.3, 25.4 cm) diameters, the booms come in both single- and double-articulated versions with a reach of up to 12 feet (3.7 m) standard, and up to 25 feet (7.6 m) for custom booms. RoboVent PowerBoom The RoboVent PowerBoom collector is fitted with an eight-inch (20.3 cm) diameter boom arm with a reach of 17 feet (5.2 m), which means workers can move within that full distance along a piece of equipment being welded. This increased mobility heightens the efficiency with which your employees are able to finish their task. The PowerBoom also creates a healthier environment by capturing fumes at the source and returning cleaner air to the facility. Introducing VentBoss by RoboVent Source capture of fumes from light-duty welding or processes such as cutting or finishing often poses an aggravating challenge. Stationary equipment is restrictive, but portable units were often ineffective until now. RoboVent has developed VentBoss, an innovative line of high-quality, portable collector units that are ideally suited to a range of operations. For more information, visit ventboss.com Sold through distribution. ROBOVENT.COM 888.ROBOVENT 29

30 Robotic Welding (SOURCE CAPTURE) Spire: Powerful filtration with the smallest footprint in the industry If you re using robotic welding cells, Spire may be the right system for you. We designed Spire especially for the most common types of welding applications in the automotive industry. Spire is a flexible, costeffective alternative to centralized ducted systems. Each Spire unit provides filtration for an individual welding cell. It s a powerful system that can keep up with the heavy demands of robotic welding in a high-production factory. Spire features: Small footprint: Our floor-saving design takes up about the same amount of space as a wire barrel. Built-in spark arrestance: Our proprietary Delta3 spark arrestance system comes standard with every unit for superior fire safety. Very low maintenance: Everything is easily accessible for fast filter changes and maintenance no special tools required. And our proprietary etell system makes maintenance headache-free. Flexible: Since the Spire units have a very small footprint, it s easy to find space for them. And whenever you need to change your floor configuration, Spire is easy to move right along with your welding cell. Spire Configuration Here is a sample plant layout with 11 welding cells each with its own Spire fume collector ducted to the Streamline Hood that is above each cell. 30 ROBOVENT.COM 888.ROBOVENT

31 Spire Small Footprint Built-in Spark Arrestance Very Low Maintenance Flexible Delta3 SparkOut Our proprietary Delta3 spark arrestance system comes standard with every Spire air filtration unit for superior fire safety. Delta3 uses centrifugal force to eliminate sparks at the source. See page 74 for details. etell Intelligent Controls Each Spire unit comes standard with etell, a revolutionary control system that learns your systems and routines, makes automatic adjustments to save energy and extend filter life and alerts you when maintenance is needed. See page 68 for details. edrive Automatic VFD (option) The edrive constantly monitors airflow and automatically adjusts the motor RPM to compensate for filter loading. Energy peaks and valleys are evened out, and energy usage is cut by 20% to 30%, while filter life is extended by as much as 30%. See page 70 for details. SafeSensor Particulate Monitoring SafeSensor is the Spire s advanced particulatemonitoring device that can detect leaks past the filters. If one should occur, SafeSensor will shut the equipment down and trigger an alarm. Supprex200 Fire Suppression System (option) This is a dual-stage system activated by smoke or heat. If smoke is detected, a fire damper closes, stopping all airflow and oxygen supply. If heat is detected, FM-200 gas is instantly deployed. Streamline Hood The RoboVent Streamline Hood is a simple, streamlined solution for hooding welding applications. Our modular design makes installation and modification quick and easy. A transparent polycarbonate top lets light in from above so no additional operator lighting is needed. And everything is built with RoboVent quality for exceptional durability. Internal Hopper Dust is collected in easy-access dual internal hoppers. Just connect a standard shop vac to the 2-inch (50.8 mm) clean-out ports to remove the particulate from the internal hoppers. You could also connect these ports to a vacuum system for continuous removal of the dust. ROBOVENT.COM 888.ROBOVENT 31

32 Robotic Welding (SOURCE CAPTURE) DeltaGate : Building a smarter ductwork system. Optimize the performance of your ducted air quality system with RoboVent DeltaGate. The DeltaGate system controls airflow to each cell individually, so you can reduce airflow and energy needs for your entire system. DeltaGate delivers: Energy savings: With DeltaGate, airflow for each section is modulated based on welding activity, reducing energy costs by up to 30%-60%, depending on production process cycles. (See chart on page 33 for example.) RoboVent Ducted System with DeltaGate Running with 70% of the stations welding: The RoboVent ducted system illustrated here shows 3 of 11 stations with their DeltaGates closed. The system includes one indoor Fusion Series collector and two outdoor Fusion Series collectors in tandem. With (3) 40 HP motors total, using the data on RoboVent savings seen in the graph, and assuming an average arc-on time of 71%, the total savings per 8-hour shift would be KWHs! Automation: The DeltaGate opens automatically when the welding arc is on, so welders don t need to think about dust control. Flexibility: DeltaGate is part of a modular ductwork system, so each gate is easy to move if your configuration needs to change. System efficiency: With DeltaGate, you can do more with less. Because airflow needs are based on actual use rather than number of stations, you ll need fewer (or smaller) dust collectors overall. How It Works A AutoSaver: Automatically modulates extraction with welding activity. B DeltaGate: Gates controlled by AutoSaver seal off ductwork sections not in use, reducing airflow requirements for the entire system. C Delta3 Spark Arrestor (option): The proprietary Delta3 spark arrestance system uses centrifugal force to eliminate sparks before they can enter the ductwork. 32

33 C B E Energy Savings with RoboVent DeltaGate Arc-on time for most robotic welding stations is between 45% and 75%. For manual stations, arc-on time may only be between 20% and 40%. So why pay for the power to run your dust collection system 100% of the time? With RoboVent s automated controls, your system is on when you need it, and off when you don t delivering significant energy savings. The DeltaGate system is tied to welding activity, but it also includes an automated airflow control that adjusts the airflow to meet what is needed for the welding stations in operation. The proprietary edrive Automated VFD works with the DeltaGates to control airflow and adjust the motor speed up or down based on system requirements. That means your system draws power only when it is needed reducing overall airflow and horsepower requirement by an average of 30%. D A F Power Savings with DeltaGate and edrive per Shift With DeltaGate and edrive Without DeltaGate and edrive: Standard operation with (2) 15 minute breaks and 30 minute lunch Looking back, I d say the ability to clean and recirculate the air and save on utility costs was the biggest, and somewhat unexpected, benefit to the new air filtration system. B.F., Welding Project Engineer, Lear Corp. D edrive: VFD (Variable Frequency Drive) controls the collector based on sensors that detect airflow requirements across the system as the DeltaGates open and close. E etell: The cloud-based etell smart control system acts as a central hub to automate and optimize performance for the entire system. F Dust collector: DeltaGate can be used with many of RoboVent s most popular dust collectors, including Spire and Fusion series collectors. Power Usage (HP) :00 8:30 9:00 9:30 10:00 10:30 11:00 11:30 Work Day (hours) Results KWHs per Day without DeltaGate and edrive: KWHs per Day with DeltaGate and edrive: KWHs Saved per 8 Hour Shift: 12:00 12:30 13:00 13:30 14:00 14:30 15:00 15:30 16: KWHs KWHs KWHs KWHs Saved per 8 hour Shift 29% on (1) Fusion Collector using DeltaGate and edrive SAVINGS 16:30 ROBOVENT.COM 888.ROBOVENT 33

34 Robotic Welding (SOURCE CAPTURE) Grid Configuration: A modular, flexible and future-proof solution When you want the efficiency and energy savings of a centralized ducted system, but with flexibility to move components if needed, consider RoboVent s Grid Configuration. Grid gives you the flexibility of mobile source capture systems with the efficiency of a centralized ducted system. It s a whole-facility solution consisting of modular, standardized ductwork and components that can be easily reconfigured as your needs change. Primary Grid Duct System The Grid system is designed using the same principles as a compressed air loop system for optimal efficiency. QuickClamp ductwork snaps together for fast and easy setup and endless configuration options similar to your kids favorite snap-together toy bricks. The Grid system is: Modular: We use standardized, modular components to make installation of your custom system fast and easy. Flexible: Move components around, expand or reduce capacity, and adjust your system to your new requirements. Modular components and QuickClamp ductwork make it easy to change your configuration as your needs change. Energy efficient: The ducted grid system only needs 70% of the airflow used by individual units, delivering significant energy savings over time. Outdoor Configuration (option) The Outdoor Grid Configuration uses the same principles the as the indoor configuration; however, collectors are typically placed outside the building and are usually larger in size. Production equipment can be added and reconfigured inside based on production needs. Oftentimes, it s several collectors placed side-byside or perhaps one larger unit that will be placed outside the facility. There are benefits to both Indoor and Outdoor configurations. While managers will like the ability to service outdoor equipment and not disturb production lines, maintenance staff will have to deal with the elements outside. 34

35 Reconfiguration is Easy with Grid Grid Fusion Connectors Modular Grid Fusion Connectors are the same size as the primary Grid ductwork section, so you can place RoboVent Fusion air filtration units anywhere on the Grid. Initial Plant Layout This image shows a plant with an initial layout and floor plan design with multiple stations and collectors. This scenario depicts what your plant layout might look like in normal working and production conditions. As production needs fluctuate and facility-specific manufacturing processes change, the system can be easily altered to accommodate needs. Grid Process Connectors Grid Process Connectors can be placed anywhere on the primary grid duct system for maximum flexibility. These Process Connectors are used to connect the stations in your process to the primary grid ductwork that is connected to the dust collectors. Production Changes As your needs change, the system could change right along with you. For example, consider a scenario where you add six new welding stations, as seen here. In order to accommodate the additional welding fume output, you simply add three additional collectors to your configuration. DeltaGate The DeltaGate is a proprietary connector for welding stations to connect to the RoboVent Grid system. We combine our proprietary Delta3 spark arrestance technology with a system of automatic gates to control airflow in and out of each cell. Airflow can be increased or decreased in specific areas as needed, and directed to clear debris out of the system. DeltaGate can be integrated into the cell prior to set up and delivery, so it s ready to go as soon as the cell is assembled on site. See page 32 for details. Station Reconfiguration Now, imagine you have moved two robotic welding stations to the other side of the plant. With the Grid system, the collectors can be easily moved to wherever they are needed. The system will automatically self balance to optimize the new configuration. ROBOVENT.COM 888.ROBOVENT 35

36 A transparent Polygal top lets light in from above. Robotic Welding (SOURCE CAPTURE) The RoboVent Streamline Hood: We ve Got You Covered The RoboVent Streamline hood is a simple solution for robotic welding and cutting cells. It s available in a variety of sizes to accommodate single or multiple robot systems and many configurations including turntable, ferris wheel and headstock/tailstock. Our modular design makes installation and modification quick and easy. The Streamline hood uses economical standardized parts that can be easily assembled, disassembled and reused. And everything is built with RoboVent quality for exceptional durability. Features and Options: Comes in eight standard sizes, from 5 x 5 (1.52 m x 1.52 m) to 20 x 20 (6.10 m x 6.10 m). Larger sizes available on demand. The entire unit ships flat for easy transport, delivery and storage. Low profile is perfect for environments with overhead cranes. Hood mounts directly to guarding. Interior cross-supports can accommodate lighting fixtures. Optional crane slots allow cranes to be used without fumes escaping. Optional duct connector hooks into your existing dust collection system. Optional spark arrestance system (Delta3) can be integrated into the duct connector for increased fire safety. RoboVent Streamline Hood with clear top hood viewed from inside enclosure. 36 ROBOVENT.COM 888.ROBOVENT

37 Types of Systems: RoboVent WeldCat By dedicating one filtration unit to each weld cell, the WeldCat distributes the job of cleaning the air. This design greatly reduces the possibility of a total system failure, along with offering potential large reductions in production delays and downtime. The RoboVent WeldCat features fast and simple installation: Just position the unit beside the weld cell, with the intake penetrating the weld cell wall. WeldCat equipment is designed to integrate with the RoboVent Flexan Enclosure system. RoboVent WeldCat. U.S. Patent # 8,800,243 RoboVent Fusion Series The RoboVent Fusion Series allows you to choose between dedicating one filtration unit to each weld cell or connecting multiple robot cells to a single RoboVent unit. The equipment may be mounted on a stand or on the plant floor and ducted to each Streamline hood over your robotic stations. Optional quick-clamp ducting can be used to make changes and reconfigurations quick and easy. Helpful Hint Hoods can be connected to RoboVent filter units (as pictured) or to an exhaust blower system. RoboVent FloorSaver The FloorSaver System provides a dedicated filtration unit for each weld cell while occupying very little space. The system is installed on top of the weld cell, supported by a heavy-duty stand. Valuable floor space is saved to allow 20% to 40% more room for production equipment. RoboVent FloorSaver System. U.S. Patent # 6,758,875 ROBOVENT.COM 888.ROBOVENT 37

38 Robotic Welding (RESISTANCE AND LASER WELDING) Resistance Welding Resistance welding, including the common methods of spot and seam welding, is a widely used process in manufacturing. This form of welding relies on the heat generated from electrical resistance between two electrodes to melt metal pieces together. As with all forms of welding, this process generates significant amounts of weld fumes, but resistance welding differs from other methods in important ways. Characteristics of Resistance Weld Fumes Resistance welding uses no filler metals, avoiding toxic fumes associated with weld wire. The heat used for resistance welding creates fine particulates that can be dangerous. These fumes often contain toxic metals, some of which have been known to cause cancer and other serious diseases. Galvanized (zinc coated) metals or metals with other coatings such as lead are associated with health risks including cancer, lung disease and metal fume fever. Coatings or residues on parts being welded, such as stamping oils or rust inhibitors, can contain substances that are dangerous when atomized and inhaled. Vigilant collection and filtration of these fumes are important for protecting workers and ensuring regulatory compliance. RoboVent Solutions for Resistance Welding RoboVent has solutions for resistance-welding operations of all kinds. RoboVent understands manufacturing facilities large and small and designs solutions specifically suited for your welding operations. If it is possible to collect your weld fumes from a single location, a source capture collector will gather and filter your air before the fumes spread. Solutions like custom hoods or fume arms can draw weld fumes and smoke away from workers and through our proprietary filter banks, returning safe, clean air to your plant. If a facility-wide solution is needed, RoboVent has a number of ambient capture solutions to mitigate weld fumes, including traditional ducted push-pull systems; the ductless, ceiling-mounted Vista360; and our Spire360 and Vortex floor units. Laser Welding Laser welding is a rapidly growing process in manufacturing and is popular due to its high level of precision and efficiency. While the initial investment for laser welding systems is higher than most other systems, the benefits are profound in terms of ability and speed. However, laser welding operations incur serious challenges when it comes to weld fumes. Because laser welders operate at such high temperatures, their weld fumes are full of very small particulates. The smaller the particulate, the more inhalable and dangerous it is for workers. While a laser welder functions in an enclosed cell one without a human operator it is still very important to capture the fumes inside the cell. Besides toxicity and other reasons to collect weld fumes, such as safety regulations, laser welders need a fume free environment so the laser can perform at its optimal level. If fume builds up near the laser, the particles within the fume can refract the laser beam, making the process both less efficient and less precise. 38 ROBOVENT.COM 888.ROBOVENT

39 Robotic Welding (HI-VAC SOURCE CAPTURE) RoboVent FlexTrac System for Robotic Welding Applications The RoboVent Flextrac hi-vac smoke-collection system is a versatile, simple and powerful solution for robotic welding smoke extraction that eliminates the need for backdraft hoods and large ductwork. The Flextrac extraction hoods are built strong but very lightweight, and are designed to make sure they don t interfere with robot movement. The hoods connect to the powerful RoboVent FlexPro hi-vac collector to extract fumes right at the source. FlexPro is designed for plug-and-play use: simply attach your hi-vac suction tube, connect to a power source and start collecting weld fumes. Capture smoke and fumes from any robotic welding application with the RoboVent Flextrac Hi-Vac System. Robotic Welding Applications: Many robotic welding applications Applications requiring extensive overhead crane use Large cells with multiple robots Assembly lines Weld Wire Feed Fume Hose RoboVent FlexTrac Robotic Tip Extraction 39

40 Welding Safety Equipment Safety Curtains Safety curtains protect nearby workers from arc flash. They re also used in sanding and other operations. Safety curtains are available as panels in a frame, panels by the roll or as a rolling track system that can be pulled back for easy access to a protected area. Use in new applications or to replace existing curtains. Supplied-Air and PAPR Hoods Fresh-air hoods provide increased protection against airborne contaminants such as hexavalent chromium, sparks, chemical and molten metal splashes and flying debris that are common in automotive manufacturing, metalworking and fabrication, chemical plants and many other industrial processes. These hoods are available in either supplied-air or powered-air-purifying-respirator (PAPR) designs. Supplied-air hoods deliver a continuous flow of air through a central (or personal) fresh-air pump using compressed-air fittings and hoses. PAPR hoods use a powered fan to pull air through filter packs on the user s belt or hood to provide fresh air. Rolling track enclosure for sanding operation. With a continuous supply of cleaner air, breathing takes less effort, thereby helping the user to remain comfortable and productive. This consistent airflow also discourages re-entrainment of noxious air and thus provides the user with a higher degree of safety. The Supplied Air Hood adds personal protection for challenging manufacturing environments. 40 ROBOVENT.COM 888.ROBOVENT

41 Metal Cutting 41

42 Metal Cutting Dust & Fumes HAZARDS AND REGULATIONS Effective Clean Air Solutions for Metal Cutting Hazards Dust and smoke created by metal cutting applications are more than just unpleasant. They can create serious health and safety hazards if not properly controlled. RoboVent designs powerful solutions to control dust, toxic metals and sparks that come from metal-cutting processes. Decades of experience have shaped these innovative designs that protect both workers and facilities. With RoboVent, you have a trusted partner on your side who can help you tailor your system to the needs of your facility, whether you are engaged in mechanical cutting, thermal applications or a combination of both. Over the decades, we have led the way in innovation for control of dust and sparks produced by metal cutting, grinding and lathing. From our Plasma Series dust collector for plasma and laser cutting to the groundbreaking Delta3 Spark Arrestance System for superior fire safety, we are creating solutions that address real-world problems for the metalworking industry. 42 ROBOVENT.COM 888.ROBOVENT Application Types and Characteristics The volume and potential problems associated with metal cutting dusts depend heavily on the cutting processes being used. The most common methods of metal cutting include: Mechanical cutting and grinding applications: These include sawing, turning, grinding and lathing, either performed with manual tools or by high speed robotic equipment. The volume of dust produced will depend on the speed and volume of production: high-speed robotic methods will produce significantly more dust than manual applications. The metalworking dust created by mechanical methods tends to be comprised of fairly large and heavy particles. Oxyfuel: Oxy acetylene cutters use a gas flame reaching temperatures of up to 3,500 degrees centigrade to melt and burn metal. By heating metal up to its melting point and then directing a stream of oxygen onto the spot, these cutters can produce a relatively clean, tightly controlled line. Laser cutting: Laser cutters use an intensely concentrated beam of light to cut through metal. The laser focuses high levels of energy into a very tightly controlled beam that uses heat to cut through the metal. The laser beam provides a high level of control and precision, allowing for clean, accurate cuts. Complex patterns can be created using computer programming to control the movement of the laser. Plasma cutting: Plasma cutting relies on a plasma torch that pumps either oxygen or an inert gas through a nozzle at high speed and simultaneously applying an electric arc. When the electricity is applied to the gas, it creates a hot plasma that melts through the metal. Plasma cutters are very useful for high throughput applications, and have precision and accuracy that come close to that of laser cutters.

43 Health and Safety Hazards of Metal Cutting Dusts Metal cutting can produce a large volume of particulates whose size depends on the application being used. The higher the temperatures used in the process, the smaller the particulates tend to be. All metalworking dusts have potential health hazards for employees. Larger particles can cause irritation of the lungs, eyes and mucus membranes in the mouth and nose. Smaller particles and smoke produced by thermal applications have hazards similar to those of weld smoke. Because these particles are drawn deeply into the lungs, they can cause serious health problems including respiratory, neurological and other systemic effects. Many of the elements in metal cutting dusts and smoke are also known carcinogens, raising the risk of lung and several other kinds of cancer. The health risks associated with metal cutting dust and smoke depends on the composition of the base metal as well as any coatings or lubricants. For example, thermal cutting of stainless steel can result in exposure to hexavalent chromium (hex chrome), a toxic compound that is associated with asthma, cancer and other health problems. Paints and coatings can also release carcinogenic or toxic elements when breathed in as fine dust or vaporized during thermal processes. If your processes involve the use of metalworking fluids (MWFs), you will need to consider the health and safety risks of associated oil mists as well. Metal cutting processes can also generate a large number of sparks, which present a serious safety hazard if not controlled. Sparks generated by metal cutting can make their way into the dust collector and ignite flammable filter media and collected particulates. Control of both dust and sparks is essential to maintaining a safe, healthy environment for metal cutting workers. Meeting Regulations for Metal Cutting Dust Control OSHA mandates that employers provide a clean, safe environment for workers. Facilities engaged in cutting and grinding applications must follow the same air quality regulations outlined for welding. Air in indoor environments must be properly ventilated or filtered to keep total particulates within safe exposure levels as outlined at In addition, employees must ensure that exposure to regulated toxic elements such as hex chrome, cadmium, beryllium and zinc are within the permissible exposure limits (PELs). OSHA defines PELs as a timeweighted average (TWA) over an 8-hour shift. Exposure limits for toxic elements in metal cutting dust and smoke are the same as those for weld fumes and can be found on the OSHA website. Effective Metal Cutting Dust Control An effective air quality system for control of metal cutting dust and fumes must take into account the volume of dust or smoke produced, the size of the particulate and the toxicity. Dust from mechanical cutting and grinding applications may be able to be controlled using a downdraft table. The relatively large size of the particulates produced means that they fall out of the air quickly. Downdraft tables work with gravity to collect metal working dust and keep work environments clean and safe. Thermal cutting applications such as laser and plasma cutting require a more robust dust collection system capable of handling a large volume of dust and smoke. The RoboVent Plaser series was especially designed for these applications. Spark control is critical for metal cutting applications, especially plasma and laser cutting. The RoboVent Delta3 was engineered to handle the large volume of sparks produced by these applications. A RoboVent system engineer can help you design the optimal system to keep your employees safe, healthy and protected. ROBOVENT.COM 888.ROBOVENT 43

44 Metal Cutting (PLASMA AND LASER CUTTING) Breakthrough Technology Changing Air Quality in Metalworking Plants From the very beginning, we have been passionate about redefining clean air technology for the future. Over the years, RoboVent has introduced a number of important breakthroughs in air cleaning technology, yet we recognized this technology could be taken to the next level to make products that are more capable, more powerful, but at the same time much simpler. We set out to bring all these aspects together and fuse them into one distinctly unique product platform. These efforts combined to create a dust collector with very low operating costs, is incredibly simple to use, and remarkably easy to install in any facility, and in any part of the world. It was from this inspiration the RoboVent Plaser Series was born. We started by re-examining metalworking dust collection from the ground up, using powerful CFD simulation software which allowed us to simulate the unseen airflow patterns in all parts of the equipment. Every part of the equipment was carefully reviewed and refined to maximize performance. By utilizing state-of-the-art fabrication technology and lean-manufacturing principles, along with fanatical commitment to quality, we have carefully structured the entire manufacturing process all the way through its culmination. This rigorous process enabled us to create a collector built to last, to minimize operational costs and to reduce maintenance. The standard features and options available such as rugged construction, vertical filters, Dynamic Pulse, edrive and RMO Technology not only ensure the longevity of the collector itself, but provide energy savings and longer filter life! etell Intelligent Controls Each Plaser unit comes standard with etell Intelligent Controls, a revolutionary control system that learns your systems and routines, makes automatic adjustments to save energy and extend filter life and alerts you when maintenance is needed. With etell, you can forget about your dust collector until it alerts you when necessary. See page 68 for details. SafeSensor Particulate Monitoring SafeSensor is the Plaser s advanced particulatemonitoring device that can detect leaks past the filters. If one should occur, SafeSensor will shut the equipment down and trigger an alarm. Dynamic Pulse System This patented system takes filter cleaning to an entirely new level. Far more than just a simple blast of compressed air, it has multiple valves working together in a computersynchronized double-pulse sequence to virtually eliminate re-entrainment while propelling the dust down into the collection area. See page 71 for details. Endurex B16 RMO Filters (option) RoboVent s Endurex B16 RMO filters use Reinforced Media Optimization and a PTFE coating to allow collected material to shed easily and quickly, extending the filter life and providing a very high filter efficiency. Engineered specifically for laser and plasma cutting applications, the Endurex B16 is rated at MERV 16, a level that approaches HEPA filtration standards. Integrated Base & Containment Unit The collector base is constructed of 1/4-inch (6.35 mm) steel for strength and stability. The 20-gallon (76 L) particulatecontainment drum locks in place with a quick-clamp mechanism. No tools are needed to empty it or to do regular maintenance. Configurations with a large-capacity 55-gallon (208 L) drum or a low-profile dust tray are standard options, and custom configurations are available upon request. 44

45 All-In-One Plaser collectors are truly all-in-one. Much more than just the sum of all the individual components, these units provide seamless integration of all the components needed, bringing together what would typically be so complex into one simple package. The energy-efficient motor is directly coupled to the airfoil blower and prewired to the onboard controls. The unit is completely assembled and powered up; thereafter, all operating systems are put through their paces before the collector is ready to leave the factory. Supprex200 Fire Suppression System (option) A dual-stage system activated by smoke and heat. If smoke is detected, a fire damper closes, stopping all airflow and oxygen supply. If heat is detected, FM-200 gas is deployed, instantly suppressing the fire. edrive Automatic VFD (option) The edrive constantly monitors airflow and automatically adjusts the motor RPM to compensate for filter loading. Energy peaks and valleys are evened out and energy usage is cut by 20% to 30% while filter life is extended by as much as 30%. See page 70 for details. Snap-Lock Filter Clamp The double-rail clamping mechanism ensures an airtight seal for every filter. The gusseted support structure is welded to the 3/16-inch (4.76 mm) reinforced tube sheet and provides over 200 pounds (91 kg) of compression force on the gasket. With this system, filter change-outs are fast, easy and require no tools. Maintenance staff will love how easy it is. Delta3 SparkOut (option) Our proprietary Delta3 spark arrestance system comes standard with every unit for superior fire safety. Delta 3 uses centrifugal force to eliminate sparks at the source, before a fire has a chance to start. See page 74 for details. 45

46 Metal Cutting (PLASMA AND LASER CUTTING) Equipment Inlets & Dust Containment The Plaser Series can be configured to meet your specific need! Dust Tray Perfect when height is a concern, the easy-to-use dust tray slides out to allow for dust removal. Not recommended for heavy loading applications. 20 Gallon (76 L) Drum Captures up to twice the dust of the standard dust tray while reducing maintenance time. Suggested for medium loading applications. 55 Gallon (208 L) Drum Captures up to three times the dust of the standard dust tray while reducing your maintenance time. Recommended for heavy loading applications. Standard Inlet Designed for direct-to-duct connections that do not have a spark arrestor, or applications where sparks are not an issue. Delta3 Inlet Ideal for limited space and high spark yield environments, this proprietary design uses centrifugal force to create a safer work environment and increased productivity all while reducing maintenance costs. Silencer The silencer option reduces the overall noise level of the collector and is available on all Plaser collectors. 46 ROBOVENT.COM 888.ROBOVENT

47 Oil Mist Solutions

48 Oil Mist & Haze HAZARDS AND REGULATIONS Effective Clean Air Solutions for Oil Mist Hazards Metalworking fluids (MWFs) are a necessary part of many manufacturing processes. But when they are aerosolized by thermal or mechanical means, the resulting mist can jeopardize worker safety and productivity. If your manufacturing process generates oil mist, it s important to work with a supplier who fully understands the health, regulatory and technical challenges that must be addressed. We re proud to be industry leaders in oil mist collection and filtration. We have spent decades studying the characteristics of oil mists and designing air quality solutions targeted to the needs of industries that use MFWs in their metalworking processes. We take a total system approach to designing an oil mist solution for your facility. From our long-lasting packed bed filters to the revolutionary design of our Clarion oil mist collectors, we provide guaranteed solutions for all kinds of oil mists. With RoboVent, you ll know that the air in your facility doesn t just look clean it is clean. Application Types and Characteristics A wide variety of manufacturing processes create oil mists but not all oil mists are the same. MWFs can be broadly characterized into four basic types: Straight Oil: Straight oils can be mineral (petroleum) or vegetable oils, and are generally used for lubrication rather than cooling. Soluble Oil: Soluble oil is composed of 30-85% refined petroleumbased oil along with emulsifiers and other additives. Soluble oils can be used for both lubrication and cooling, but can result in more smoke and residues. Semisynthetic: These fluids contain 5-30% petroleum-based oil along with a complex emulsifier package. They provide good lubrication and heat reduction, and are cleaner than soluble oils. Synthetic: Synthetics are composed of detergent-like compounds rather than petroleum. They are generally the cleanest option and offer good heat reduction. In addition to oil type, it s important to know whether your oil mist is thermally or mechanically generated. Mechanically generated mists result from processes that do not generate excessive heat, such as metalworking lathing. Particles are around 10 microns in diameter and are relatively easy to capture due to their large size. Thermally generated mists come from heat-generating applications such as wet grinding, hot forging and oil quenching. These mists look like smoke and are submicron: ten to one hundred times smaller than mechanically generated droplets. This makes them much harder to filter. Depending on the chemistry involved and the process you are using, the characteristics of the mist (e.g. particle size, concentration, stickiness ) can vary widely. These characteristics have important implications for the type of filters needed, air flow requirements and other aspects of system configuration. 48 ROBOVENT.COM 888.ROBOVENT

49 Health and Safety Hazards of Oil Mists Uncontrolled oil mists can create an unappealing and unsafe work environment. Aerosolized coolants and lubricants can spread throughout the facility, leaving a haze in the air and a layer of grease over floors and surfaces. This not only leaves a bad impression on workers and customers, but can also create potential slip-and-fall hazards in the facility. Oil mists can also have serious health concerns. Specific health impacts vary depending on the chemicals in the fluid and the size of the particles generated by the manufacturing process. Some mists may contain chemicals that irritate the skin, eyes, nose, throat or lungs. The sub-micron aerosolized particles created by thermal processes can be easily breathed in by workers. Depending on the chemistry of the fluid and the level of exposure, workers exposed to oil mists may develop sore throats, nosebleeds, coughing and wheezing, shortness of breath and other cold- or flu-like symptoms. Prolonged exposure has been linked to asthma, chronic bronchitis, chronically impaired lung function, hypersensitivity pneumonitis (HP), fibrosis of the lung and cancer. Workers may also be exposed to other disease-causing pathogens if MWF is contaminated by microorganisms. It s important to protect workers from the effects of oil mist exposure. Appropriate collection and filtration can reduce the potential health risks and increase worker satisfaction and productivity. Meeting Regulations for Oil Mist Control Currently, two OSHA air contaminant permissible exposure limits apply to MWFs: For mineral oil mists: 5 mg/m 3 for an 8-hour time weighted average (TWA) For all other metalworking fluids: 15 mg/m 3 (8-hour TWA) There are also additional recommended exposure limits: The National Institute for Occupational Safety and Health (NIOSH) recommends an exposure limit of 0.4 mg/m 3 for thoracic particulate mass as a 10-hour TWA. The American Conference of Governmental Industrial Hygienists (ACGIH) threshold limit value for mineral oils is 5 mg/m 3 for an 8-hour TWA and 10 mg/m 3 for a 15-minute shortterm exposure limit. The OSHA Metalworking Fluids Standards Advisory Committee recommends an 8-hour TWA exposure limit of 0.4 mg/m 3 thoracic particulate or 0.5 mg/m 3 total particulate. Effective Oil Mist Control Oil mists and solid particulates behave totally differently and require different approaches to collection. Dust collection equipment made for weld fumes and other solid particulates will not be effective against oil mists. Packed bed filters, also called coalescing filters, are the most effective filters for most oil mists. These filters are designed to capture tiny droplets on the fibrous media, which then coalesce into larger droplets and drain into a collection pan. They continue to work even when fully saturated, so they have a long life compared to typical filter media, often up to two or three years. The RoboVent Clarion Series uses a revolutionary design that safely and efficiently removes aerosolized oil-based contaminants from the air, while minimizing maintenance time and costs. Our engineers can help you analyze your processes and the characteristics of your oil mist and recommend the right system and configuration for your application. ROBOVENT.COM 888.ROBOVENT 49

50 Oil Mist Solutions (SOURCE CAPTURE) Clarion by RoboVent A Breakthrough in Oil Mist Collection Technology The Robovent Clarion Series is a revolutionary design in industrial air-cleaning equipment that efficiently separates solid particulate in oil and water in the most demanding manufacturing environments. Traditional oil-mist collectors rely on dated technologies such as centrifugal, pocket filters, individual cartridge or panel filters, electrostatic precipitators and others with limited success. We believed there was a better way, so we investigated the entire process in order to redesign the way oil mist is collected. The result is the RoboVent Clarion Series. Robust Construction Integrated Controls The CFX Source Capture Clarion unit can be very simply controlled by connecting to the dedicated terminal or interlock on the CNC machine. Upgrades to an independent motor starter and disconnect, as well as our proprietary etell Intelligent Controls, are available. edrive Automatic VFD (option) The edrive constantly monitors airflow and automatically adjusts the motor RPM to compensate for filter loading. Energy peaks and valleys are evened out, cutting energy usage by approximately 40% and increasing filter life by as much as 30%. See page 70 for details. Superior Filter Technology Exceptional Performance Guaranteed Satisfaction Snap-Lock Filter Clamp The Clarion double-rail clamping mechanism ensures an airtight seal for every filter. The gusseted support structure is welded to the 3/16-inch (4.76 mm) reinforced tube sheet and provides over 200 pounds (91 kg) of compression force on the gasket. With this system, filter change-outs are fast and easy, require no tools and can be performed from outside the filter cabinet. 50

51 D C All-In-One Motor/Blower Combination Clarion oil mist collectors are truly all-in-one. Much more than just the sum of all the individual components, these units are a seamless integration of all the components needed, bringing together what would typically be so complex into one incredibly simple package. The energy-efficient motor is directly coupled to the airfoil blower and prewired to the onboard controls. The unit is completely assembled and powered up, and then all operating systems are put through their paces before the Clarion oil mist collector is ready to leave the factory. SafeSensor Particulate Monitoring (option) SafeSensor is an advanced particulate-monitoring device that can detect leaks that make it past the filters. If one should occur, SafeSensor will shut the equipment down and trigger an alarm. B A Supprex200 Fire Suppression System (option) This is a dual-stage system activated by smoke or heat. If smoke is detected, a fire damper closes, stopping all airflow and oxygen supply. If heat is detected, FM-200 gas is instantly deployed, suppressing the fire. Rugged Cabinet Design Clarion oil mist collectors feature a rugged modular cabinet design that aligns with our signature protocol. The cabinet is fully welded 14-gauge steel with heavy-duty components. The entire cabinet and all structural components are backed by the 15-year warranty that is RoboVent s assurance of quality. Clarion Air Filtration Process Air enters the bottom section of the collector A and larger droplets B fall out before entering the filter. The air is then pulled up through the packed-bed media filter C. The packed-bed media filter separates the remaining oil from the air and clean air is returned to the plant through the integrated blower and motor D. RoboVent s all-in-one configuration coupled with the proprietary packed-bed filter media makes oil mist filtration easy! Single Packed Bed Media Filter RoboVent s packed-bed media filter design simplifies the filter change-out process, cutting maintenance costs. The filters come in three different depths and two different efficiency ratings. The Clarion packed-bed media filter range ensures that you will receive the right filter for your application. Helpful Hint Ask us how our packed-bed filters can reduce your filter replacement and maintenance costs. ROBOVENT.COM 888.ROBOVENT 51

52 Oil Mist Solutions (AMBIENT SYSTEMS) RoboVent Clarion Ambient Systems Clarion Vortex System Made especially for oil mist applications, the Clarion Vortex System is based on a proprietary design that creates a circulating airflow to effectively capture and filter oily particles in a plant. Cleaner air is then re-introduced to the plant in a seamless process. The system utilizes a unique mechanism consisting of eight to 12 nozzles that can be adjusted directionally to maximize the efficiency at which the air is cleaned. Is The Clarion Vortex System right for you? There are many benefits to installing a vortex system in your facility: It allows for the air to be filtered and cleaned in situations where source capture of oil mist is not possible or feasible. It does not interfere with overhead cranes or other obstructions that cause trouble for the ventilation systems. No ductwork is required, which lowers installation costs and improves sight lines and visual appeal. It reduces collector noise levels by decreasing static pressure. Integrated Controls All units come complete with a built-in motor starter, disconnect and minihelic gauge. Upgrades to our proprietary etell Intelligent Controls are available. All control panels are built in our UL Certified panel shop in Sterling Heights, Michigan. Clarion mwrap Cartridge Filters RoboVent s Clarion series Vortex collectors use square flange cartridge filters designed specifically for oil mist. Our specially designed mwrap filters are built to last using RMO Technology and proprietary filter media. Rugged Cabinet Design Clarion oil mist collectors feature a rugged modular cabinet design that aligns with our signature protocol. The fully welded 10-gauge steel cabinet has a 3/16-inch (4.76 mm) tube sheet and 1/4-inch (6.35 mm) thick steel for the base. The entire cabinet and all structural components are backed by the 15-year warranty that is RoboVent s assurance of quality. Typical Clarion Vortex System: The system is engineered to create a plant-wide environmental vortex that turns the air at a consistent and steady rate. The design of our Vortex system is especially suited to the capture of dirty air in the most challenging places. 52

53 Vortex Return Air Nozzles and Integrated Silencer Plenum The Clarion Vortex series oil mist collectors come equipped with an integrated silencer and return air nozzles. This eliminates the need for return air ductwork and cuts down installation time. Clarion Vortex return air nozzles can be adjusted to create the airflow patterns that will work best in your facility. The integrated silencer ensures that your Clarion oil mist collector is running at a reasonable sound level. Supprex200 Fire Suppression System (option) This is a dual-stage system activated by smoke or heat. If smoke is detected, a fire damper closes, stopping all airflow and oxygen supply. If heat is detected, FM-200 gas is instantly deployed, suppressing the fire. edrive Automatic VFD (option) The edrive constantly monitors airflow and automatically adjusts the motor RPM to compensate for filter loading. Energy peaks and valleys are evened out, cutting energy usage by approximately 40% and increasing filter life by as much as 30%. See page 70 for details. Snap-Lock Filter Clamp The Clarion double-rail clamping mechanism ensures an airtight seal for every filter. The gusseted support structure is welded to the 3/16-inch (4.76 mm) reinforced tube sheet and provides over 200 pounds (91 kg) of compression force on the gasket. With this system, filter change-outs are fast and easy, require no tools and can be performed from outside the filter cabinet. Vortex Intake Plenum Clarion Vortex series oil mist collectors are equipped with an integrated intake plenum. This Intake plenum spreads the air entering the collector to maximize filter life and removes any need for intake ductwork. Combined with the Vortex Return Air Nozzles, the Vortex Intake Plenum creates a solution for ductless full-plant ambient oil mist concerns. Helpful Hint RoboVent Clarion Vortex assembles in 60 minutes on-site.* * Collector Assembly only. Does not include time for ducting, electrical connections, etc. ROBOVENT.COM 888.ROBOVENT 53

54 Oil Mist Solutions RoboVent Clarion Filters No one knows filters better than RoboVent. Our packed-bed and cartridge filters have been specially engineered for oil mist applications to provide you with the very best filtration protection for your plant and employees. We combine superior filter media and engineering innovation to create efficient, durable filters that stand up to the most demanding manufacturing environments. Packed Bed Filters Why use two, three or four different filters when you can have one filter that does it all? Our packed-bed filter media have been especially designed to maximize filter life and efficiency for oil mist applications. Engineered media layers separate the oil from the air Folded layered filter creates drain-back and allows the separated oil to drain out of the filter Coalescing filters continue to work even when fully saturated, extending the useful life of the filter and reducing maintenance and lifecycle costs Filter Specifications Square filter with a range of depth and media options: Depths for light, medium and heavy applications Medium-efficiency and high-efficiency media options available Vortex Series mwrap Filters Our innovative Vortex Series mwrap cartridge filters have a proven track record for high efficiency filtration of oil-laden particulate in a variety of manufacturing processes. Endurex D12 RMO media and a proprietary pre-filter layer combine to make our filters more durable, effective and efficient than other alternatives and provide extended filter life. Specially formulated media with resin impregnated fibers for extreme durability against liquids and oils Proprietary pre-filter layer engineered for efficient drain-back and separation of the oil droplets from the air stream RMO technology keeps filter pleats at optimal spacing and the integral support ribs ensure that pleats do not collapse, maximizing filter life and durability Filter Specifications Square flange cartridge filter Filtration efficiency down to 0.15 microns 210 F / 99 C max operating temperature Square flange for easy filter replacement Helpful Hint Replacement filters can be purchased through the RoboVent ClientCare program or let us replace them for you! 54 ROBOVENT.COM 888.ROBOVENT

55 Other Dust Collection

56 Other Dust Collection (DUST AND FUME CONTROL) Your Partner in Dust Control No matter what kind of dust is produced in your facility, RoboVent can help. The Fusion Series has proven solutions for all types of industrial dusts, from silica and fiberglass to carbon black and talc. The Benefits of Clean Air Controlling dust isn t just a regulatory requirement it s good business. Besides safeguarding the health of your employees, improving air quality leads to increased worker productivity and other benefits, as well. Did you know: A study examining the impact of indoor air pollution on worker productivity in the United States found a 4.2% improvement in productivity when indoor air contaminants were reduced. Poor indoor air quality is estimated to cause six additional lost workdays per year for every ten employees. The Occupational Safety and Health Administration (OSHA) has estimated the annual nationwide cost savings related to increased air quality could be $15 billion. Better dust control results in efficiency and productivity improvements, cost reductions in operations and maintenance and reduced incidence of property damage. Clean environments lead to better recruiting, retention and worker satisfaction, especially among younger workers. Of course, you ll want to make sure you are meeting all OSHA regulations for dust control. However, many manufacturers are going further in order to meet other business goals. The American Conference of Governmental Industrial Hygienists (ACGIH) has published guidelines for control of dozens of different kinds of dusts, which are based on the latest science and often more stringent than OSHA regulations. No matter what your dust control goals are, the Fusion Series can help you get there. Dust Collection Applications Carbon Black Carbon black, widely used in rubber applications and in pigments for plastics, paints and inks, appears in its refined states as an odorless black powder notable for its high surface area. It can cause severe irritation to the eyes, skin, nose, throat and lungs, in addition to severe cough, headache, chest pain and fatigue. High concentrations of carbon black dust create a very unpleasant environment for employees and accumulate on surfaces throughout the factory. It also accumulates in lungs, where it may be linked to cancer. The Fusion Series can reduce carbon black dust levels to well below OSHA regulations and keep your factory environment clean, pleasant and healthy. Silica Dust OSHA recently cut their permissible exposure limits for silica in half, to just 50 µg/m 3 as an 8-hour TWA. Will you be ready? The Fusion Series is perfect for facilities involved in cutting or grinding of bricks, tiles, masonry or concrete, as well as glass and tile manufacturers, processes using abrasive sandblasting, and other applications that expose workers to silica dust. We can help you meet the new standards and reduce the risks of lung cancer, silicosis and other chronic respiratory diseases for your workers. RoboVent rooftop units for a plastic cutting process. 56

57 Talc Fine, soft talc powder finds its way into hundreds of products and processes, from dry lubricants for industrial applications to cosmetics, pharmaceuticals, paper, ceramics and even foods. While it is not currently classified as a carcinogen, the small size of talc grains allows them to be inhaled deep into the lungs where they can cause talc pneumoconiosis or make their way into other body systems. For this reason, it is important to keep talc exposure for workers low. The Fusion Series can easily handle extra-fine talc grains and ensure that your manufacturing environment meets OSHA regulations. Fiberglass Fiberglass produces significant amounts of dust when it is sanded, ground or cut. Workers who are exposed to fiberglass dust during industrial processes can develop irritation of the skin, eyes and respiratory system. Smaller fibers may be able to make their way deep into the lungs, where their long-term health effects are unknown. Companies working with fiberglass need powerful capture and filtration to collect fiberglass dust particles of various sizes and keep them from accumulating in the air and on factory surfaces. The Fusion Series is well suited to handle fiberglass dust produced by a variety of processes. Abrasive Blasting Abrasive-blasting applications range from wheel blasters and air blasters to cabinet blasters. Because each utilizes a variety of abrasive-blasting media including sand, garnet, steel, plastic and shot each application must be reviewed before an equipment recommendation can be made. Special consideration is required for silica-sand blasting and aluminum blasting, and we have a range of products suitable for these applications. RoboVent unit collecting dust from a fiberglass sanding operation. ROBOVENT.COM 888.ROBOVENT 57

58 Other Dust Collection (DUST AND FUME CONTROL) Pharmaceutical Pharmaceutical manufacturers must maintain dust-free environments to avoid cross contamination of medications as well as potentially dangerous exposures to pharmaceuticals for workers. Without proper dust control, workers can be exposed to anesthetics, hormones, anti-viral drugs and more, which can lead to skin rashes, birth defects, organ toxicity, fertility problems or worse. The Fusion Series can help you ensure that your facility meets Current Good Manufacturing Practice (CGMP) for cleanliness, worker safety and product purity. Plastics Like in fiberglass operations, RoboVent units can handle plastic dust as well. Combined with the RoboVent Fusion collector and the Dynamic Pulse mechanism, the Endurex RMO Filter Technology makes it simple to capture dust from plastic cutting operations. Consider your plastic dust issues solved! Recycling No matter the material you are recycling aluminum, plastic, paper, etc. RoboVent Fusion Series dust collectors can handle it. Using cyclone separators and drop boxes, they make it possible to collect the dust as a recyclable material, increasing the efficiency of your plant. Other Applications: Aluminum Aluminum Blasting Aluminum Oxide Blast Rooms Brick Making Cast Iron Grinding Chemical Processing EAW Spraying Fine FRP Dust Fine Powders Flame Spray Fumed Silicon Glass Making Iron Casting Sand Iron and Chrome Laser Cutting Fumes Light Carbon Dust Metal Flame Spray Mica Nickel Dust PVC Grinding Shot Blast Materials Styrene Dust Tile Manufacturing Titanium Dioxide Tobacco Dust Toner Welding Fumes Wheel Blasting Aluminum recycling operations benefit from the use of a RoboVent collector. 58 ROBOVENT.COM 888.ROBOVENT

59 General Ventilation

60 General Ventilation (MAKE-UP AIR & EXHAUST SYSTEMS) Make-Up Air Systems Most factories require some fresh air to replace process gases that are being exhausted. Makeup-air systems allow air to be brought back into the plant and heated to desired temperatures even during the coldest months of the year. This overcomes the common problem of negative pressure within the facility. RoboVent supplies direct-fired makeup-air heaters to any industry. Whether they re used in a paint booth or to heat an industrial facility or commercial kitchen, these compact, economical heaters provide large volumes of tempered fresh air. All units feature 16-gauge galvanized steel construction and have large lifting lugs for easy installation. The burner compartment has one-inch (2.5 cm) thick insulation to keep cold air out and make the unit easier to start on cold winter days. Controls are built in, and a remote-control panel can be placed anywhere you want outside your office or mounted to the side of a paint booth. The systems are available as direct fired, which brings the air directly across the burners for maximum efficiency, or indirect fired, which isolates the burners from the airstream so the air can be 100% recirculated back into the plant. Exhaust Blowers RoboVent exhaust blowers are designed for commercial and industrial applications that require high volumes of air at low static pressures. Whether they re placed on the roof, in a wall or as part of a paint booth, RoboVent supplies them all. Whatever the application, we can install and maintain your exhaust system to best guard against negative pressure in your building s atmosphere. 60 ROBOVENT.COM 888.ROBOVENT

61 High Pressure Exhaust Blowers for Long Duct Runs and Hoods Primarily used to move clean air through complex or large duct systems, high pressure blowers ensure the proper circulation of air in your facility. What may seem like a necessary complete industrial ventilation system overhaul can sometimes be remedied with proper high pressure blower integration. These high pressure blowers allow for long duct runs and hoods that typical fans don t have the power to draw through. RoboVent high pressure blowers feature all-welded construction and are either direct drive or belt driven. Blowers will be custom-sized for your specific application and industrial ventilation equipment needs. Engine Exhaust Hose Reels RoboVent s hose reels are the premier solution for vehicleexhaust fume extraction. Hose reels offer a convenient and efficient method for extracting harmful emissions from all types of service areas. Hose reels are either motor operated or manual spring retractable, and a variety of tailpipe adapters attach them to all types of vehicles. The reels are offered in standard four-, five-, six- and eight-inch (10.2, 12.7, 15.2 and 20.3 cm) hose diameters and are supplied completely assembled and ready for installation. The reels may be connected with ductwork to a central exhaust system, or each reel may be supplied with a direct-mount fan. Also, ask us about custom applications, including eight- through 18-inch (45.72cm) diameter hose configurations. RoboVent hose reels may be mounted in three positions: from an overhead support structure, from a side support structure, or on the floor. Ceiling mounts are most common; however, wall mounts and floor mounts are options as well. ROBOVENT.COM 888.ROBOVENT 61

62 General Ventilation (MAKE-UP AIR & EXHAUST SYSTEMS) High Volume Low Speed Fans The Difference Is in the Design The RoboVent Blade, a high volume, low speed fan, is changing the way industrial and commercial buildings are ventilated. They re an excellent primary ventilation system in certain open-air facilities such as agricultural buildings, sheds and stadiums; and they re an excellent supplement to existing HVAC systems in a wide range of large, open spaces such as warehouses, distribution centers, processing plants, retail centers, athletic facilities and elsewhere. RoboVent Blade fans are powerful, quiet and efficient at moving large volumes of air. During winter months our fans improve the distribution of warm air, and during the summer months, in reverse operation they circulate cool air more effectively. The results are increased comfort for building occupants while lowering the energy usage typically required for big spaces, especially for buildings with overhead doors or truck bays that cause a constant and expensive drain on HVAC systems. RoboVent Blade Profile 62 ROBOVENT.COM 888.ROBOVENT

63 Fusion Series Dust & Fume Collectors

64 Dust & Fume Collectors RoboVent Fusion Series: Breakthrough Technology That Is Changing Air Quality in Manufacturing Plants From the very beginning, we have been passionate about redefining clean air technology for the future. Over the years RoboVent has introduced a number of important breakthroughs in air cleaning technology, yet we recognized that this technology could be taken to the next level, to make products that are more capable, more powerful, but at the same time much simpler. We set out to bring all these things together and fuse them into one distinctly unique product platform. All of these efforts combined to create a dust collector that has very low operating costs, is incredibly simple to use and remarkably easy to install in any facility, and in any part of the world. It was from this inspiration that the Fusion Series was born. We started by re-examining dust collection from the ground up, using powerful CFD simulation software that allowed us to simulate the unseen airflow patterns in all parts of the equipment. Every part of the equipment was carefully reviewed and refined to maximize performance. By utilizing state-of-the-art fabrication technology and lean-manufacturing principles, along with an almost fanatical commitment to quality, we have carefully structured the entire manufacturing process all the way through its culmination: a rigorous 137-point quality-control checklist. This rigorous process enabled us to create a collector that is built to last and minimize operational and maintenance costs. The standard features and options available such as rugged construction, vertical filters, Dynamic Pulse, etell Intelligent Controls, edrive and RMO Technology not only ensure the longevity of the collector itself, but provide energy savings and longer filter life! etell Intelligent Controls Each Fusion Series unit comes standard with etell Intelligent Controls, a revolutionary control system that learns your systems and routines, makes automatic adjustments to save energy and extend filter life and alerts you when maintenance is needed. With etell, you can forget about your dust collector until it calls you. See page 68 for details. SafeSensor Particulate Monitoring SafeSensor is the Fusion Series advanced particulatemonitoring device that can detect leaks past the filters. If one should occur, SafeSensor will shut the equipment down and trigger an alarm. Dynamic Pulse System This patented system takes filter cleaning to an entirely new level. Far more than just a simple blast of compressed air, it has multiple valves working together in a computer-synchronized double-pulse sequence to virtually eliminate re-entrainment while propelling the dust down into the collection area. See page 71 for details. Endurex RMO Filters RoboVent s Endurex RMO filters use Reinforced Media Optimization and a rigorous quality control system to guarantee performance. In addition to RMO Technology a wide selection of media is available including high performance cellulose, NanoFiber and PTFE, so that the filters can be tailored specifically to the application. Integrated Base & Containment Unit The collector base is constructed of 1/4-inch (6.35 mm) steel for strength and stability. The 20-gallon (76 L) particulatecontainment drum locks in place with a quick-clamp mechanism. No tools are needed to empty it or to do regular maintenance. Configurations with a large-capacity 55-gallon (208 L) drum or a low-profile dust tray are standard options, and custom configurations are available upon request. 64

65 All-In-One Fusion Series collectors are truly all-in-one. Much more than just the sum of all the individual components, these units are a seamless integration of all the components needed, bringing together what would typically be so complex into one incredibly simple package. The energy-efficient motor is directly coupled to the airfoil blower and prewired to the onboard controls. The unit is completely assembled and powered up, and then all operating systems are put through their paces before the Fusion Series collector is ready to leave the factory. Supprex200 Fire Suppression System (option) This is a dual-stage system activated by smoke or heat. If smoke is detected, a fire damper closes, stopping all airflow and oxygen supply. If heat is detected, FM-200 gas is instantly deployed, suppressing the fire. edrive Automatic VFD (option) The edrive constantly monitors airflow and automatically adjusts the motor RPM to compensate for filter loading. Energy peaks and valleys are evened out, and energy usage is cut by 20% to 30% while filter life is extended by as much as 30%. See page 70 for details. Snap-Lock Filter Clamp The Fusion Series double-rail clamping mechanism ensures an airtight seal for every filter. The gusseted support structure is welded to the 3/16-inch (4.76 mm) reinforced tube sheet and provides over 200 pounds (91 kg) of compression force on the gasket. With this system, filter change-outs are fast and easy, require no tools and can be performed from outside the filter cabinet. Rugged Cabinet Design The Fusion Series features a rugged modular cabinet design that aligns with our signature protocol. The fully welded 10-gauge steel cabinet has a 3/16-inch (4.76 mm) tube sheet, 1/4-inch (6.35 mm) thick steel for the base and a Schedule 40 compressed-air pressure vessel. The entire cabinet and all structural components are backed by the 15-year warranty that is RoboVent s assurance of quality. Helpful Hint RoboVent Fusion Series collectors assemble in 60 minutes on-site.* * Collector assembly only. Does not include time for ducting, electrical connections, etc. ROBOVENT.COM 888.ROBOVENT 65

66 Dust & Fume Collectors FEATURES & OPTIONS All-in-One Complete Packaged Product RoboVent collectors come as a complete package. And they come completely assembled. With RoboVent you don t just get crates of components showing up at your dock; you get a finished product that has already been run through its paces and fully tested by our trained factory technicians. Space Savings Reduce the footprint of the system, and improve the aesthetics at the same time! Whether your ventilation equipment will be located inside or outside your plant, saving space can save you money, too. Convenience Save yourself the aggravation of sorting out the finger-pointing when things don t go together the way everyone hoped! RoboVent collectors have built-in blowers and built-in electrical controls, so there is minimal installation. Simply connect power and compressed air, and connect the touch-screen control board via a standard Ethernet cable (no wiring required). All components have been selected with low maintenance in mind, and are professionally assembled by our factory technicians. Reduced Installation Costs You ll realize significant savings by purchasing a preassembled RoboVent collector. Be sure to add up all your costs, and you will find that thousands of dollars of costly on-site electrical wiring can be eliminated, plus a lot of extra ductwork and installation time. Quality Control Every RoboVent collector has been carefully engineered and all components have been selected to make sure they will work together effectively and efficiently. Our trained factory people assemble and test RoboVent equipment every day. The blower, the pulse valves, the control panel and the wiring in between have all been checked to make sure that everything is working properly. By removing the guesswork, we can give you the best warranty in the industry with confidence: up to five years on all parts! The RoboVent assurance means your satisfaction is guaranteed. The RoboVent Complete Package The Conventional System Blower compartment Clean air back into the plant Compressed air connection Electrical controls Dirty air into the collector Field wiring to Collector Clean air back into the plant Electrical power connection Dirty air into the collector Electrical power connection Compressed air connection Field wiring to Blower Separate Blower Separate Controls 66 ROBOVENT.COM 888.ROBOVENT

67 RoboVent Vertical Filters Vertical Filters vs. Horizontal Filters Even dispersal of particulate over entire filter Increase Filter Life with Proper Filter Orientation The advantages of using vertical filters are significant. Vertical filters allow the dust to shed off the filter and fall directly down into the containment system, while the dirt from horizontal filters tends to shed off the bottom twothirds only. The top third of a horizontal filter is lost in the first 10% to 20% of the filter s life. The life of the remaining two-thirds of the filter is drastically reduced due to the increase in air-to-cloth, resulting in an overall loss of 30% to 40% of the intended filter life. The only advantage in a horizontal-filter dust collector is the ease of manufacturing, as it is much simpler to build than a vertical-filter dust collector. 33% LONGER Extend Filter Life with RoboVent Vertical Filters Helpful Hint Save time! Vertical filters change out quicker thanks to large access doors and easy slide-in/ slide-out square filter flanges. RoboVent Vertical Filter Orientation: 16 Months Horizontal Filter Orientation: 12 Months Horizontal Filters (or slightly inclined) Top third of filter lost due to inability to shed particulate. RoboVent's vertical filter configuration allows for even particulate dispersal which maximizes filter life. ROBOVENT.COM 888.ROBOVENT 67

68 Dust & Fume Collectors FEATURES & OPTIONS etell Intelligent Controls: Advanced Air Quality Controls for Dust Collection Systems With patent-pending etell Intelligent Controls from RoboVent, they ll tell you what they need and when they need it. It s not about preventative maintenance it s about predictive maintenance. etell eliminates costly and time-consuming maintenance routines and targets your efforts where they are truly needed. Just install the cloud-based software once, and let it tell you what needs to be done each month, or in real time. It will even tell you how to perform maintenance activities with easy-to-follow video instructions delivered right when you need them. etell is the only control system that is: Predictive: etell can predict exactly how much life is left in your filters and when maintenance tasks should be performed based on your system use patterns. Cloud-based: Our cloud-based application gives you anywhere, anytime visibility for all of your equipment from multiple facilities on a single application. Smart: etell learns your systems and processes and makes real-time adjustments to save energy and extend filter life. The etell Advantage Eliminate standard preventative maintenance routines and schedules. Cut maintenance costs by focusing only on what is actually needed. Access step-by-step video instructions so your team can perform maintenance activities without prior training. Track performance, energy use and maintenance needs for all of your dust collectors on your smart phone or tablet. Save money with smart software that learns your processes and adjusts energy use and self-cleaning cycles to reduce operational costs. Manage Multiple Collectors Now you can view and manage dust collectors across all of your facilities in one easy application. etell lets you monitor the entire facility and see the alerts and alarms for all of your machines in one place. Predictive Analytics etell uses advanced machine learning to analyze your systems and processes and make smart predictions on how future activities will impact filter life and maintenance needs. It uses this information to make simple, automatic adjustments that save energy and reduce costs. Easy-to-understand reports allow you to monitor energy use, filter life and other key metrics for each machine in your network. Reminders and Emergency Alerts Get alerts and reminders right on your smartphone, tablet or computer. etell will alert you if your dust collector needs immediate attention and send timely maintenance reminders. You can set your communication preferences so you can be reminded as often (or as seldom) as you like. 68

69 Maintenance Scheduling Plant managers can easily monitor system performance and plan maintenance schedules based on each collector s needs. etell lets you track updates, alerts and maintenance tasks for every collector in one place and generate a task list for each machine in your facility. Collector Dashboard Service technicians can pull up the etell dashboard to get a full list of maintenance recommendations specific to each collector. The dashboard tells you exactly what needs to be done, when it should be completed and approximately how long each task should take. It even provides links to helpful video tutorials right at the point of use. Video Tutorials and Help The application comes pre-loaded with links to online support materials, helpful supportive materials and general video tutorials for your system, allowing you to self-diagnose and address any item. Factory Support 24/7 Our staff will be alerted if a problem is not addressed immediately, so we can help you stay on top of any issues that should arise. Rather than taking the time to fix any issues yourself, simply call RoboVent to have one of our trained technicians service your equipment on site. etell Premium Services (optional) With Premium services, you ll have all of the standard etell features plus remotely turning equipment on/off and a more intuitive machine maintenance package. RoboVent etell Intelligent Controls are the standard control package on RoboVent collectors. The RoboVent etell App is available on Android and ios devices through the Google Play and Apple App Stores. The etell Website is available when etell Server is installed in your facility. Preferences Customize your reports and alerts setting for your preferred frequency and level of detail. You can get detailed reports for in-depth performance analysis or just set it and forget it and let your dust collectors call you only when they need you. etell lets you adjust system preferences for your workflow and management style. ROBOVENT.COM 888.ROBOVENT 69

70 Dust & Fume Collectors FEATURES & OPTIONS edrive Automatic VFD With the RoboVent edrive, your collector s airflow is monitored and the motor s RPM is automatically adjusted to compensate for filter loading. As you can see in the graph to the right, a collector running without edrive uses more energy in the beginning of the filter s life cycle than a collector with edrive does. Benefits of the RoboVent edrive include: Less stress on filter media, which leads to longer filter life Decrease in energy usage by 20% to 40% Improved equipment performance Decreased filter costs Decreased maintenance costs Using the RoboVent edrive with your dust collector will compress and straighten energy peaks and valleys, cutting energy usage by approximately 40% and increasing filter life by as much as 30%. The RoboVent edrive Saves You Money by Decreasing Energy Use and Extending Filter Life In the example on the right, this 10 HP unit would be using KWs per hour of operation. This example shows that you would save 41% over the 18 month period. For filters in this example you have increased the filter life by 4 months or 29% Filter Life Savings. RoboVent vs. Make-Up Air Are You Exhausting Your Profits? It s not every day you have the ability to reduce operating costs by 65%! We re mindful of efficiencies gained through clean air technology and we help our customers consistently achieve these savings. Heavier costs are avoided by combining multiple airflow processes into one, thus providing efficiencies during system operation. RoboVent systems simultaneously clean and re-circulate the air in your facility eliminating the need for additional sources of air or make-up air to be pumped into the facility. It also reduces the need for expensive exhaust systems. Our systems keep your working environment free of dust and other harmful particulates to help you run a much more efficient facility and reap the profits! Helpful Hint ROI on the edrive varies from 8 to 14 months depending on energy costs. Power Savings with edrive Power Usage (HP) With edrive Without edrive Filter Life (Months) Results Total KWHs without edrive: Total KWHs with edrive: Total KWH s Saved: Power Savings with RoboVent edrive 44,742 KWHs 26,396 KWHs 18,346 KWHs Filter Life Savings with edrive Filter Loading (%) With edrive Without edrive Filter Life (Months) Results Filter Life without edrive: Filter Life with edrive: Filter Life Saved: Filter Life Savings with RoboVent edrive 14 Months 18 Months 4 Months 70 ROBOVENT.COM 888.ROBOVENT

71 $105,600 $102,800 Annual Energy Cost Comparison (50,000 CFM) $36,500 RoboVent Operating Cost Northern Climate Exhaust + Make-Up Operating Cost (Heat) Southern Climate Exhaust + Make-Up Operating Cost (A/C) Filters and Upkeep Gas Electric Dynamic Pulse System Extend Filter Life with Dynamic Pulse Proprietary, computerized and efficient, the RoboVent Dynamic Pulse System uses a rapid-fire technique. The synchronized action of the pulsing mechanism virtually eliminates any re-entrainment of dust going from one filter to the next; instead, it causes the dust to fall into the containment tray or drum. The patent-pending Dynamic Pulse System ensures your filters are used to maximum capacity! Saving filter life by shedding particulate effectively and eliminating re-entrainment, the synchronized Dynamic Pulse System has proven to be 1.5 times more effective than typical pulsing systems. As you can see in the charts below, we tested this system thoroughly. With the Dynamic Pulse System, 30% more dust was removed from the filters than with a typical pulsing system! Also, it had 82% effectiveness vs. 57% effectiveness with the standard pulsing system! RoboVent Dynamic Pulse System Testing Particulate In Standard Pulse System Testing Particulate Out % EFFECTIVE GALLONS GALLONS (22.7 L) (18.5 L) Particulate In Particulate Out % EFFECTIVE 3.4 GALLONS GALLONS (22.7 L) (12.9 L) Perfectly Synchronized Pulsing Virtually Eliminates Re-entrainment of Dust. See the RoboVent Dynamic Pulse System in action by visiting Particulate Volume Controlled Variables Number of Cycles Dynamic Pulse System Recovered Volume Standard Pulse System Recovered Volume Test 1 6 Gal. (22.7 L) (1) Cycle; 12 Cartridges Test 2 6 Gal. (22.7 L) (1) Cycle; 12 Cartridges Test 3 6 Gal. (22.7 L) (1) Cycle; 12 Cartridges Test 4 6 Gal. (22.7 L) (1) Cycle; 12 Cartridges Test 5 6 Gal. (22.7 L) (1) Cycle; 12 Cartridges Test 6 6 Gal. (22.7 L) (1) Cycle; 12 Cartridges Test 7 6 Gal. (22.7 L) (1) Cycle; 12 Cartridges Test 8 6 Gal. (22.7 L) (1) Cycle; 12 Cartridges Test 9 6 Gal. (22.7 L) (1) Cycle; 12 Cartridges Average Recovered Volumes: ROBOVENT.COM 888.ROBOVENT 71

72 Dust & Fume Collectors FEATURES & OPTIONS RoboVent Endurex Premium Cartridge Filters Whether you have an ultra-fine dust, metal cutting fumes or an aggressive abrasive particulate, RoboVent has you covered. RoboVent s premium Endurex filter cartridges have been engineered to provide you the very best filtration protection for your plant and employees. Durable and proven, our filter media have been designed for outstanding performance in filtering fumes, smoke, dust, oil haze and other particulates/ pollutants created during virtually any manufacturing process. It s No Longer About Media Quantity. It s About Media Optimization. Endurex RMO is truly the future in efficient filtration. By widening the pleat spacing in our proprietary filter media and ensuring that the pleats remain apart, we maximize the surface area of media available to dust and fume particles while maintaining the highest level of filtration efficiency. The result is a reduction in static pressure and a superior release of particulate. In short: longer filter life, using less media. Extended Filter Life with Endurex RMO Filters Filter P ( W.G.) RoboVent RMO Filter Standard Filter Hours of Operation Endurex RMO: The Next Generation of Filters Re-engineered to maximize efficiency while reducing static pressure, patent-pending Endurex Reinforced Media Optimization (RMO) brings filter technology into the 21st Century. A B B RMO support keeps the filter pleats at optimum spacing, allowing for maximum loading on the media, and more effective pulse cleaning. RMO support ribs (shown in blue above) are continuous for the full length of the pleats ensuring no pleat collapse. RMO structures ensure media surface area is maximized, and the entire filter is used to its full potential. Traditional Filter Design A Results Filter Life of Standard Filter: Filter Life of Endurex RMO Filter: Filter Life Extended: Extended Filter Life with Endurex RMO Filters 3200 Hours 5000 Hours 1800 Hours In traditional filter design, the pleats are often pinched closed. The clean area seen on the inside of these pleats indicates that the dirty air never reached this media, resulting in less effective loading and ineffective pulse cleaning and as a result, short filter life. 72 ROBOVENT.COM 888.ROBOVENT

73 Filter Media Breakdown Compare the various RoboVent Endurex filter media and see which one is suited for your particular application. Endurex M11 Economy MERV 11 Endurex D12 DefendEx MERV 12 Endurex W13 WeldEx MERV 13 Endurex A15 Nanofiber MERV 15 Endurex B16 PTFE MERV 16 The Endurex M11 is RoboVent s Economy filter for applications where a lowcost filter is preferred. The M11 media is a fire retardant media that is good up to Merv 11 efficiency. Standard cellulose/poly media Good filtration for minimum cost RMO technology Efficient for particulate down to 0.1 micron in size Flame retardant media 176 F / 80 C Max operating temperature The Endurex D12 is a specially blended media for oil-laden particulate. The media is specifically formulated with an extremely durable phenolic resin system where each fiber is individually coated instead of a film formation. Special formulated media with resin impregnated fibers for extreme durability against liquids/oils Good for oily smoke applications RMO technology Filtration efficiency down to 0.15 microns Non flame retardant media 210 F / 99 C Max operating temperature The Endurex W13 is RoboVent s standard filter for welding applications. The WeldEx media has proved itself reliable, being used in thousands of RoboVent collectors today. A fire retardant media is good up to Merv 13 efficiency. Formulated cellulose/ poly media Excellent filtration for minimum cost RMO technology Efficient for particulate down to 0.1 micron in size Flame retardant media 176 F / 80 C Max operating temperature The Endurex A15 is RoboVent s high quality cellulose/polyester blend that provides superior filtration efficiency and long life in welding applications. Every filter is fire retardant and uses Nanofiber technology to achieve long filter life. Nanofiber membrane laminated to cellulose/ poly substrate Long filter life Low differential pressure RMO technology High efficiency for particulate down to 0.1 micron in size Flame retardant media 149 F / 65 C Max operating temperature A premium filter offering superior performance in both filter efficiency and longevity. The PTFE coating allows collected material to shed easily and quickly, extending the filter life and providing a very high level of filter efficiency. The Endurex B16 is rated at MERV 16, a level that approaches HEPA filtration standards. PTFE membrane laminated to polyester spunbound substrate Excellent particulate release RMO technology Ultra high efficiency for very fine particulate 0.1 micron and below Non flame retardant media 200 F / 93 C Max operating temperature Applications: Ambient Dust Blasting General Industrial Nuisance Dust Weld Smoke Other Light Loading Dust Applications: Agglomerative Dust Hygroscopic Moist Some Abrasive Dust Very Oily Weld Fume Applications: Ambient Dust General Industrial Metalizing Dusts with Slight Moisture Content (such as Weld Fume) Applications: Air Blasting Fumed Silica General Industrial Metal Grinding Dust Metalizing Pharmaceutical Weld Smoke Wheel Blasting Applications: Chemical Processing Food Processing General Industrial High Production Wheel Blasting Laser and Plasma Cutting Pharmaceutical Polishing Weld Smoke ROBOVENT.COM 888.ROBOVENT 73

74 Dust & Fume Collectors FEATURES & OPTIONS Delta3 : Stop fires before they start. Sparks are a natural byproduct of welding, grinding and metal cutting but if they are left uncontrolled, the resulting fires can have devastating consequences. Now you can protect your workers, equipment and facilities with the most advanced and efficient spark arrestance system available on the market today. Delta3 is built on groundbreaking technology that uses centrifugal force to kill sparks before they have a chance to grow. By stopping fires right at the source, Delta3 creates a safer work environment and vastly reduces the risk of avoidable work accidents. And our innovative design will help you keep productivity high, operating costs low and maintenance costs to a minimum. How? Our Delta3 units are self cleaning to minimize maintenance costs and system downtime. They also provide superior air flow compared to traditional spark arrestance systems, which lowers energy costs and maximizes the life of your filters. Delta3 delivers: Excellent spark control Self-cleaning operation Low pressure drop Helpful Hint Under extensive lab testing, the Delta3 proved to be more effective than leading competitors at preventing sparks from entering the filter cabinet. Visit for a video demonstration. Delta3 vs. The Competition: Delta3 stamped out the competition in comparative tests. It s the only technology in our comparative testing that extinguished 99.9% of sparks for welding, grinding and plasma cutting applications. Delta3 can be in-line duct mounted or collector mounted, depending on your configuration. C A Breakthrough in Engineering Delta3 is based on an advanced patent-pending technology that represents a major breakthrough in spark arrestance. RoboVent Engineers used Computational Fluid Dynamics (CFD) to accurately model how embers would respond to different spark arrestor designs. We simulated hundreds of design iterations and put the best ones to test in real-world comparison studies against existing competitive systems. The result? Delta3 was the only unit that provided complete, reliable spark arrestance in comparative studies, controlling 99.9% of sparks. A B C B Centrifugal action drives sparks and embers against the outer wall of the device, stripping off the thermal envelope that surrounds them so that they are rapidly cooled and extinguished. High air velocities are maintained on the surfaces inside the device, eliminating particulate deposits so the unit is constantly cleaning itself. Internal air turbulence is minimal, which lowers the restriction to airflow. This reduces the energy required for operation and improves filter life. A 74 ROBOVENT.COM 888.ROBOVENT

75 Supprex-200 System: Is Your Welding Operation A Fire Hazard? According to the latest research conducted by the National Fire Protection Association, welding and cutting operations are responsible for nearly 6% of the fires that occur in manufacturing facilities. It s no surprise: Sparks and flames are an inherent part of cutting and welding operations. Every company involved in these processes must take important precautions to increase safety and minimize the risk of fire. With this potential for fire in mind, RoboVent has developed its advanced SparkOut technology to help prevent fires that can occur in dust-collection systems. RoboVent s focus has always been to stop the fire before it starts. Prior to installing the RoboVent system, a lot of our units would catch on fire. Now our fires have been virtually eliminated. T.S., Weld Assemble Manager, Flex-N-Gate Corp. Fires: An accident waiting to happen Fires require three main elements in order to ignite or be sustained: Fuel Source Oxygen Heat or Ignition Source OXYGEN HEAT FUEL FIRE TRIANGLE In a Fume Collection system servicing a welding or metal cutting process, these three elements come together when a hot spark makes its way into the collector and comes in contact with a filter cartridge. Fume Collection systems move air at high speed and therefore provide an excellent source of Oxygen, so it is critical to employ a system that effectively kills the sparks (the Ignition source) before they reach the dust particulate (the Fuel). Four Lines of Fire Prevention with the RoboVent SparkOut System STEP 1: Delta3 The Delta3 A quickly extinguishes sparks created through metal cutting processes. The proprietary design represents many years of extensive field testing and performance under heavy manufacturing conditions. STEP 2: SafeSensor The SafeSensor B particulatemonitoring device detects smoke or dust leaks past your filters. If a leak occurs, the system shuts the equipment down and sets off an alarm C. STEP 3: Supprex-200 Damper The Supprex-200 Damper System D closes when smoke is detected, stopping the oxygen from feeding the fire. If a fire is present, it is typically contained to one filter and the Supprex-200 does not disperse. STEP 4: Supprex-200 Fire Suppression If and when heat is detected, FM-200 gas is released at the location of the fire. There is little or minimal cleanup after a fire with the Supprex-200 System E. A Delta3 SparkOut B SafeSensor Monitor C SafeSensor Horn Alarm & Strobe Light D E Supprex-200 Damper Supprex-200 Fire Suppression C E B D A 75

76 Dust & Fume Collectors FEATURES & OPTIONS Deflagration System Reducing Fire and Explosion Risks from Combustible Dusts Combustible dust explosions can cause employee injuries, deaths and destruction of entire buildings. In a factory environment, a combination of combustible dusts, spark-generating process and confined spaces can easily become a recipe for disaster if appropriate risk mitigation steps are not taken. What is a Combustible Dust? The National Fire Protection Agency (NFPA) defines combustible dust as any finely divided solid material that is 420 microns or smaller in diameter and presents a fire or explosion hazard when dispersed and ignited in air. If such a dust is suspended in air in the right concentration, under certain conditions, it can become explosible. Left uncontrolled, such dusts may migrate from the point of production/release, subjecting other parts of the facility to fire and explosion hazards. The RoboVent Deflagration System Many RoboVent dust collectors, including Fusion and Plaser series collectors, can be easily configured with a deflagration system to reduce the risks associated with combustible dusts. Each component of the deflagration system is designed to minimize potential damage in case of a fire or explosion inside the collector and prevent flames from spreading back into the facility. When designing a Deflagration System, RoboVent s engineering team takes into careful consideration all aspects needed for NFPA combustible dust compliance. Our engineering process includes: Explosive testing in accordance with ASTM standards to determine if your dust is combustible. PHA (Process Hazard Analysis), sometimes known as risk assessment, is conducted for any dust with a KST value of greater than 200 bar-m/sec. RoboVent s engineering team incorporates explosion relief panels and other devices into our dust control systems to help you comply with the latest NFPA standards. Meeting Safety Regulations NFPA has issued a number of standards related to prevention of fire and dust explosions that manufacturers producing combustible dusts must follow. NFPA Standard 652, the Standard on Fundamentals of Combustible Dusts, provides an overview of required safety and risk mitigation practices and directs you to other resources and standards for explosion venting and/or explosion prevention. 76 ROBOVENT.COM 888.ROBOVENT

77 How Combustible Dust Explosions Happen Combustible dust explosions are relatively rare, but when they happen, they can be catastrophic. According to the Occupational Safety & Health Administration (OSHA), five elements are needed for a combustible dust explosion: Combustible dust (fuel) Ignition source (heat) Oxygen in the air (oxidizer) Dispersion of dust particles in sufficient quantity and concentration Confinement of the dust cloud IGNITION CONFINEMENT OF DUST CLOUD Delta3 Spark Arrestance System Our proprietary spark arrestance system prevents sparks from entering the dust collector where they could ignite filter media or combustible dusts. Delta3 works with your deflagration system for added fire and explosion safety. See pages 74 for details. Isolation Valve The isolation valve acts like a check valve to prevent the deflagration (pressure wave) from propagating through the ductwork back into the facility. Explosion Vent If an explosion occurs inside the collector, the explosion vent will rupture to release excess pressure. This allows the energy from the explosion to be safely directed away from the building to minimize structural damage and injuries. Rotary Airlock The purpose of the rotary airlock is to prevent the deflagration (pressure wave) from propagating out the hopper in the event of an explosion, protecting personnel and property. DISPERSION OF DUST PARTICLES COMBUSTIBLE DUST OXYGEN IN AIR Source: OSHA DUST FIRE AND EXPLOSION If the quantity of dust in suspension in the air that is moving through a dust collection system is above what is called the minimum explosive concentration (MEC), then the suspension can potentially explode in the presence of an ignition source (e.g., a welding gun). Unlike most gas or vapor explosions, the major damage of a dust explosion often results from the secondary event, which happens when a primary explosion within a piece of equipment or local to an ignition source spreads to remote areas due to involvement of dust accumulations outside of the equipment. The initial explosion can dislodge more accumulated dust into the air or damage a dust containment system, again releasing more dust. ROBOVENT.COM 888.ROBOVENT 77

78 Dust & Fume Collectors FEATURES & OPTIONS Equipment Inlets & Dust Containment The Fusion Series can be configured to meet your specific need! Dust Tray Perfect when height is a concern, the easy-to-use dust tray slides out to allow for dust removal. 20 Gallon (76 L) Drum Captures up to twice the dust of the standard dust tray while reducing maintenance time. Suggested for medium loading applications. 55 Gallon (208 L) Drum Captures up to three times the dust of the standard dust tray while reducing your maintenance time. Suggested for heavy loading applications. Standard Inlet Designed for direct-to-duct connections that do not have a spark arrestor, or applications where sparks are not an issue. Vortex Inlet Maximizes air circulation throughout your weld environment without sacrificing space. Suggested for use with our unique Vortex Louver system. Delta3 Inlet Ideal for limited space and high spark yield environments, this proprietary design uses centrifugal force to create a safer work environment and increased productivity all while reducing maintenance costs. 78 ROBOVENT.COM 888.ROBOVENT

79 Other Configurations & Options Silencer The silencer option reduces the overall noise level of the collector and is available on all Fusion Series collectors. Vortex Package The Vortex Package is a stand-alone unit built for cleaning ambient air with adjustable nozzles, creating optimal airflow. Package consists of Vortex Louver, as shown above, mounted to the SparkOut intake chassis. WeldPro Package The WeldPro Package is a stand-alone workstation that includes a SparkOut Intake and a Flexan Hood for capturing smoke from a variety of applications. Recommended Upgrades and Options Abrasive-Inlet Package AutoSaver Sensor Barrel Level Sensor edrive Automatic VFD etell Intelligent Controls eq: Air Quality Monitoring Explosion Panels* Isolation Valve* HEPA After-Filter Hopper Gate Noise-Reduction Packages On-Board Air Compressor Outdoor-Prep Packages Rotary Air-Lock* Service Platform with Ladder Sprinkler Head Port Supprex-200 Fire-Suppression System * See pages for more information on Combustible Dust Hazards in Dust Collection and our Deflagration System. Service and Ongoing Support RoboVent 24 Hour Hotline: 888.ROBOVENT The RoboVent 24-hour hotline is available seven days a week. We understand your requirement for production and stand ready to help at any time. Maintenance Contracts Available Sophisticated air-filtration equipment represents a costly investment in your plant and the health of your employees. Proper maintenance is critical to the performance of that investment. RoboVent preventative maintenance programs provide the regularly scheduled expert maintenance needed to properly maintain your air-filtration and dust-collection systems, and greatly reduce the risk of unexpected system breakdowns and production delays. Best Warranty in the Industry RoboVent Fusion Series collectors come with the Best Warranty in the Industry: 15 Years on the Cabinet and up to 5 Years on Components. See Warranty Document for further details. ROBOVENT.COM 888.ROBOVENT 79

80 Dust & Fume Collectors FEATURES & OPTIONS RoboVent ICE (Integrated Cooling Equipment) Get Clean, Cool Air with RoboVent ICE The patent-pending RoboVent ICE system goes beyond traditional HVAC by integrating dust collection and air conditioning. Combining the two systems produces major benefits for your workers and facility all of which boosts profitability for your business. Available in both ductless and ducted options, RoboVent ICE is the perfect solution to keep your plant clean and cool. Create a Healthier Working Environment Attract and Retain Top Talent Reduce Maintenance on Equipment Increase Your Bottom Line by Minimizing Productivity Loss Prevent Worker Heat Stress and Dehydration Summer Heat Burns $$$ Hot weather is not only uncomfortable, it can also be expensive. As temperatures go up, productivity goes down. Let RoboVent ICE protect your profits by helping you beat the heat of summer and prevent productivity loss. Without RoboVent ICE Temperature 85 F (29 C) Productivity Loss 8.8% With RoboVent ICE Temperature 75 F (24 C) Productivity Loss 0.0% Do the Math for 30 Workers: $1.41 Lost Productivity Per Hour Per Person x 30 Workers x 40 Hours Per Week (Single Shift) x 17 Summer Weeks (May - August) = $28,764 Productivity Loss Per Summer ($ Per Worker Per Summer) $0 Productivity Loss Per Summer RoboVent ICE can keep your plant a comfortable 75 F (24 C) with low humidity. The result is no loss in productivity from the heat, a decrease in sick days and an increase in morale. The choice is clear Do the Math. Temperature Productivity Loss 77 F (25 C) 0.0% 80 F (27 C) -3.2% 85 F (29 C) -8.8% 90 F (32 C) -14.3% 95 F (35 C) -19.9% 100 F (38 C) -25.4% 105 F (41 C) -31.0% Source: Seppänen, O., Fisk, W. J. and Lei, Q. H. (2006) 80 ROBOVENT.COM 888.ROBOVENT

81 Maintenance, Replacement Filters & Equipment Upgrades

82 Maintenance Programs ClientCare Service Program: Service options for every need and budget Whether you want us to handle all monthly preventative maintenance for you, or simply need regular equipment checks to make sure everything is in top condition, we can help you find a service package that meets your needs. We offer three levels of ClientCare service. Our service packages let you leverage our expertise so you can reduce the burden on your maintenance staff, control your maintenance budget and stay focused on your core business. RoboVent ClientCare helps us budget better. We can predict our costs and proactively plan for maintenance downtime. RoboVent ClientCare has kept our equipment running at 100% outside of scheduled maintenance. Facilities Engineer, equipment manufacturing facility Helpful Hint Sign up for the RoboVent CompleteCare program, and get a full lifetime warranty on your RoboVent equipment for as long as the program is in place! CompleteCare Maintenance Program With the CompleteCare Maintenance Program, you can leave everything to us. Depending on your equipment needs and usage, our technicians will come in monthly, bi-monthly or quarterly to change filters, conduct routine maintenance, and troubleshoot emerging issues. CompleteCare is a comprehensive maintenance package designed to give you peace of mind, extend the life of your equipment and reduce the maintenance burden on your staff. One flat rate per service call regardless of frequency to help you budget better (filters charged separately) Lifetime Warranty included for the life of the contract on all parts and labor (excluding filters) Full electronic service report provided within 48 hours of your service so you can monitor equipment issues and budgets Additional visits (inspection, trouble shooting or repair) available at additional cost Sample CompleteCare Checklist: Stop blower, reset digital read-out to zero, restart blower, record Delta-P value Stop blower, set controller to rapid pulse, pulse down for minutes Start blower, record new Delta-P value Inspect system Check for blower / motor vibrations Check pulse valves Check controller function Replace parts as necessary Record estimated volume of collected dust particulate Empty drum/tray (as needed) Clean spark arrestance baffle filters (if applicable) Change cartridge filters as required Record filter pressure and filter life Visual inspection of ductwork 82

83 Equipment Certification Program Our Equipment Certification Program, offered on a quarterly, bi-annual or annual basis, will help you extend the life of your equipment and protect the safety of your workers with regular inspections by certified RoboVent technicians. We ll identify any emerging issues and make proactive maintenance or repair recommendations to prevent unexpected downtime and ensure that your equipment is running at top efficiency. 50-point check of your entire system Detailed report provided within 72 hours of inspection Client review meeting within two weeks of the inspection to address concerns and opportunities Recommended inspection intervals: - Equipment less than 3 years old: annual - Equipment between 3 & 8 years old: bi-annual - Equipment more than 8 years old: quarterly Warranty is not extended nor offered through this program Three Levels of Service Choose the level of service that s right for you. ClientCare Service Quality Check Program If you would rather conduct your preventative maintenance in-house, our ClientCare Service Quality Check Program will ensure that your maintenance team is performing world-class PM service that meets all RoboVent standards. Our technicians can come in monthly, quarterly or bi-annually to review service records and make recommendations for your maintenance staff. We ll make sure that maintenance staff are conducting the right services on the right schedule to maintain your equipment in top condition and help them troubleshoot any emerging issues they have identified. Detailed report provided within 72 hours of inspection Warranty is not extended nor offered through this program It s more cost-effective for me to let RoboVent take care of their equipment. They know what it needs and they can do it faster. My in-house talent is better spent elsewhere. Project Engineer, automotive parts manufacturing facility CompleteCare Maintenance Program Equipment Certification Program ClientCare Service Quality Check Program Service/Inspection Report Service Recommendations 50-Point System Check Client Review Meeting Full Warranty Change Filters Perform Preventative Maintenance Review of Service Records Troubleshooting RoboVent Takes Full Responsibility ROBOVENT.COM 888.ROBOVENT 83

84 Replacement Filters Filter Media Breakdown Compare the various RoboVent Endurex filter media and see which one is suited for your particular application. Endurex M11 Economy MERV 11 Endurex D12 DefendEx MERV 12 Endurex W13 WeldEx MERV 13 Endurex A15 Nanofiber MERV 15 Endurex B16 PTFE MERV 16 The Endurex M11 is RoboVent s Economy filter for applications where a lowcost filter is preferred. The M11 media is a fire retardant media that is good up to Merv 11 efficiency. Standard cellulose/poly media Good filtration for minimum cost RMO technology Efficient for particulate down to 0.1 micron in size Flame retardant media 176 F / 80 C Max operating temperature The Endurex D12 is a specially blended media for oil-laden particulate. The media is specifically formulated with an extremely durable phenolic resin system where each fiber is individually coated instead of a film formation. Special formulated media with resin impregnated fibers for extreme durability against liquids/oils Good for oily smoke applications RMO technology Filtration efficiency down to 0.15 microns Non flame retardant media 210 F / 99 C Max operating temperature The Endurex W13 is RoboVent s standard filter for welding applications. The WeldEx media has proved itself reliable, being used in thousands of RoboVent collectors today. A fire retardant media is good up to Merv 13 efficiency. Formulated cellulose/ poly media Excellent filtration for minimum cost RMO technology Efficient for particulate down to 0.1 micron in size Flame retardant media 176 F / 80 C Max operating temperature The Endurex A15 is RoboVent s high quality cellulose/polyester blend that provides superior filtration efficiency and long life in welding applications. Every filter is fire retardant and uses Nanofiber technology to achieve long filter life. Nanofiber membrane laminated to cellulose/ poly substrate Long filter life Low differential pressure RMO technology High efficiency for particulate down to 0.1 micron in size Flame retardant media 149 F / 65 C Max operating temperature A premium filter offering superior performance in both filter efficiency and longevity. The PTFE coating allows collected material to shed easily and quickly, extending the filter life and providing a very high level of filter efficiency. The Endurex B16 is rated at MERV 16, a level that approaches HEPA filtration standards. PTFE membrane laminated to polyester spunbound substrate Excellent particulate release RMO technology Ultra high efficiency for very fine particulate 0.1 micron and below Non flame retardant media 200 F / 93 C Max operating temperature Applications: Ambient Dust Blasting General Industrial Nuisance Dust Weld Smoke Other Light Loading Dust Applications: Agglomerative Dust Hygroscopic Moist Some Abrasive Dust Very Oily Weld Fume Applications: Ambient Dust General Industrial Metalizing Dusts with Slight Moisture Content (such as Weld Fume) Applications: Air Blasting Fumed Silica General Industrial Metal Grinding Dust Metalizing Pharmaceutical Weld Smoke Wheel Blasting Applications: Chemical Processing Food Processing General Industrial High Production Wheel Blasting Laser and Plasma Cutting Pharmaceutical Polishing Weld Smoke 84 ROBOVENT.COM 888.ROBOVENT

85 Industrial Replacement Filters High-Quality Filters for Every Brand and Application Do you need filters for your industrial processes? No problem. No matter what kind of equipment you have installed, we can help you keep it humming. We maintain a large inventory of high-quality replacement filters for nearly every application and brand of equipment. Our ClientCare team can help you find the right filters to keep your equipment running at optimal performance, no matter who made it. For a complete inventory of available industrial replacement filters, or for help finding filters for uncommon applications, contact your RoboVent ClientCare representative. Here are some of the filters we commonly keep in stock: Air Filters Framed Fiberglass and Polyester Disposable Panels Pleated Filters Merv 7-Merv 11 Polyester Roll Media, Pads, Ring Panels and Links Polyester Cubes Synthetic and Fiberglass Media Bag Filters Rigid Cell Filters Minipleated and Minipleat V-Cells HEPA and ULPA Box Filters Carbon-Bulk Carbon and Impregnated Media Spray Booth Filters Spray Booth Filters for All Booth Makes & Models Prefilter Bags, Cubes and Polyester Link/Ring Panels Ceiling/Intake Blankets and Ring Panels Exhaust Filter Roll Media and Cut Pads-Polyester & Fiberglass 2nd Stage Exhaust Cube and Bag Filters Dust Collection Filters Replacement Cartridge and Bag Filters for All Dust Collection Systems Full Range of Specialty Media for All Application Requirements Full Range of Filters for Oil Mist Collection: Metal Mesh, High Efficiency Bags and HEPA Filters. Compressed Air Filtration Complete Line of Compressor and Compressed Air Filter Elements for all Major Brands Compressor Spin-On Lube Filters, Air Intake Cartridges and Panels and Air/Oil Separators Refrigerated and Desiccant Dryers Standard and custom sizes are available for all of the applications listed. Call 888.ROBOVENT today for a specialist to visit your facility and provide a custom quote! ROBOVENT.COM 888.ROBOVENT 85

86 Equipment Upgrades Equipment Upgrades: Innovative products to maximize safety, efficiency and control. At RoboVent, we are leading the industry in development of new products and systems to make air quality equipment safer, more efficient and longer lasting. From fire suppression to mobile monitoring, we offer options to help you reduce operating costs, mitigate risks and get the most out of your RoboVent equipment. These product enhancements can be added or retrofitted to most RoboVent dust collectors. Ask your RoboVent Representative for details. Delta3 Upgrade The key to fire prevention is to stop sparks before they enter the dust collector. RoboVent has long been an industry leader in spark arrestance, with proprietary technology that quickly extinguishes sparks created in the welding process. Delta3 is built on groundbreaking technology that uses centrifugal force to kill sparks before they have a chance to grow. Delta3 can be mounted on the dust collector or in line with the ductwork. It delivers: Self-cleaning operation to minimize maintenance costs and system downtime Superior airflow and low pressure drop for lower energy costs and longer filter life Delta3 was the only unit that provided complete, 100% spark arrestance in comparative studies. Helpful Hint Under extensive lab testing, the Delta3 proved to be more effective than leading competitors at preventing sparks from entering the filter cabinet. Visit for a video demonstration. etell Upgrade etell puts control of your air quality systems in the palm of your hand! etell helps you save energy, prolong filter life and reduce operational costs by learning your processes and trends and making automated adjustments where they will have the most benefit. The cloud-based app connects to your RoboVent system using Bluetooth and delivers reports to your phone or tablet. An easy, intuitive dashboard lets you monitor equipment efficiency and system performance metrics 24/7 from anywhere on the planet. etell delivers: Continual monitoring of inline sensors to track system performance Automated adjustments to increase efficiency and improve filter life Real-time push notifications and alerts when manual service is required Predictive analytics to help you plan proactive maintenance and avoid unscheduled shutdowns Ask us about etell Premium Services for Remote Tech Support and SMS text and notifications for selected alarms. 86 ROBOVENT.COM 888.ROBOVENT

87 Electronic Control Systems Upgrade Maximize the efficiency of your air quality equipment with innovative control systems from RoboVent. Our Variable Frequency Drive (VFD) systems are designed to help you save money by decreasing energy use and extending filter life. edrive Automatic VFD Upgrade RoboVent edrive monitors your collector s airflow and automatically adjusts the motor s RPM to compensate for filter loading. Benefits of the RoboVent edrive include: Less stress on filter media, which leads to longer filter life Decrease in energy usage by approximately 40% Improved equipment performance Decreased filter costs Helpful Hint RoboVent's eq Air Quality Monitoring System can save you up to 85% off your equipment electrical costs an ROI of 6 months or less! Decreased maintenance costs eq Air Quality Monitoring Upgrade The RoboVent Air Quality Monitoring System is an innovative system Helpful Hint ROI on the edrive varies from 8 to 14 months depending on energy costs. that monitors the current air quality in your facility and automatically turns your RoboVent systems on or off. On when you need it, off when you don t the Air Quality Monitoring System allows you to save money on your electrical costs by operating your RoboVent systems only when they are needed. Power Savings with edrive Power Usage (HP) With edrive Without edrive Filter Life (Months) Results Total KWHs without edrive: Total KWHs with edrive: Total KWH s Saved: Power Savings with RoboVent edrive 44,742 KWHs 26,396 KWHs 18,346 KWHs Filter Life Savings with edrive Filter Loading (%) With edrive Without edrive Filter Life (Months) Results Filter Life without edrive: Filter Life with edrive: Filter Life Saved: Filter Life Savings with RoboVent edrive 14 Months 18 Months 4 Months ROBOVENT.COM 888.ROBOVENT 87

88 Manual Welding Fume Extraction Integrated Cooling Equipment Robotic Welding Fume Collection Maintenance Programs Oil Mist Extraction Full-Plant / Ambient Air Cleaning Systems Dust Collection Systems Mobile Dust Collectors Laser & Plasma Cutting Fume Collection Aftermarket Replacement Filters Improving Lives through Clean Air ROBOVENT.COM 888.ROBOVENT INFO@ROBOVENT.COM 2017 RoboVent Product Group, Inc v2.0 RVP01