OWNER S MANUAL INDUSTRIAL ELECTROSTATIC AIR CLEANER MODEL: SH-SSP-300
KNOW YOUR EQUIPMENT READ THIS MANUAL FIRST. Your SMOG-HOG system should provide many years of trouble-free service. This manual will help you understand the operation of your SMOG-HOG unit. It will also help you understand how to maintain it in order to achieve top performance. For quick future reference, fill in the system and filter information in the spaces below. Should you need assistance, call the United Air Specialists, Inc. customer service number shown below. To expedite your service, have the following information available when contacting UAS. UAS ORDER #: UNIT MODEL #: UNIT SERIAL #: SYSTEM ACCESSORIES: INSTALLATION DATE: UNITED AIR SPECIALISTS, INC. CUSTOMER SERVICE 1-800-252-4647
TABLE OF CONTENTS Page SAFETY PRECAUTIONS ii 1. IMPORTANT NOTICE... 1 2. DESCRIPTION... 1 3. INSTALLATION... 1 3.1 Inspection Note 3.2 Installation Planning 3.3 Unit Mounting 4. START-UP AND OPERATION... 2 5. MAINTENANCE... 2 5.1 Cleaning Instructions 5.2 Replacing Damaged Ionizer Wires 6.TROUBLESHOOTING... 3 6.1 Tools Required 6.2 System Components 6.3 Before Testing 6.4 Troubleshooting Procedures 7.REPLACEMENT PARTS... 4 7.1 Replacement Parts List... 5 8. TROUBLESHOOTING TABLE... 6 9. FIGURES... 7-9 10. WIRING DIAGRAM... 10 WARRANTY i
SAFETY PRECAUTIONS We have provided many important safety messages in this manual and on the. Always read and obey all safety messages.! This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others. All safety messages will follow the safety alert symbol and the word DANGER, WARNING, or CAUTION. These words mean:! DANGER! WARNING! CAUTION CAUTION Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. IMPORTANT SAFETY INSTRUCTIONS! WARNING To reduce the risk of fire, electric shock, or injury when using the air cleaner, follow these basic precautions: Use two or more people to move and install the air cleaning system. The air cleaner must be properly grounded. Disconnect power before servicing. Replace all access panels before operating. Wear protective clothing and safety glasses when handling collection components or servicing the air cleaner Electrical connections should only be made by qualified personnel and be in accordance with local and national codes and regulations. Do not use in explosive atmospheres. Use nonflammable cleaners. Do not collect emissions which are explosive. Keep flammable materials and vapors, such as gasoline, away from air cleaner. The unit should be inspected frequently and dirt removed to prevent excessive accumulation which may result in flash-over or fire damage. The air cleaner should not be used for support of personnel or material. Operate only in a safe and serviceable condition. ii
1. IMPORTANT NOTICE This manual contains important safety information and precautionary measures. It is impossible to list all potential hazards associated with every air cleaning system in each application. Proper use of the equipment must be discussed with United Air Specialists, Inc. (UAS) or your local Representative. Operating personnel must be aware of, and adhere to, the most stringent safety procedures. Unit Specifications: Unit Weight: 91 lbs. (41 kg) Electrical Service: 100-120V/1P/60Hz/2.5A (Max.) Nominal AirFlow: 510 m3/hr (300 cfm) For Indoor Use Only 2. DESCRIPTION (See figures 1 and 2) This unit is a self-contained, two-stage, air cleaner designed to remove dry or oily airborne contaminants from industrial work areas. Operating on the principle of electrostatic precipitation, it pulls air past a mechanical pre-filter, charges and collects airborne particulate, then exhausts clean air to the environment. Pre-filters serve the dual purpose of trapping large particles and diffusing the air stream evenly into the precipitator components at low, controlled velocity. Air passes through an ionizing section where nearly all particulate is charged; then on to a collecting section where charged particles are repelled from similarly charged plates and drawn to ground plates. Agglomerated particles separated from collection plates during unit startup are trapped on an after-filter, allowing clean air to pass through the system blower at all times. The Model SH-SSP-300 may be ducted directly to the contaminant source or un-ducted to remove particles from the general environment. The SH-SSP-300 can be suspended from the ceiling or cradle mounted, depending on the application. Ionizing and collecting sections operate on high DC voltages (direct current) at a maximum current of 5.0mA. The high voltage creates a powerful field for trapping small to sub-micron particles. In SH-SSP-300 units, ionizing and collecting occur in a single mechanical component called a unicell. At startup, the unit s power supply charges the unicell while the unit blower begins to move air through the unit. All high-voltage wiring is external to the component enclosure. 3. INSTALLATION 3.1 INSPECTION NOTE Upon receipt of your unit, check for any shipping damage. A damaged carton indicates that the equipment may have received rough handling during shipping that may have caused possible internal damage. Notify your delivery carrier and enter a claim if any damage is found. 3.2 INSTALLATION PLANNING Locating the Unit: Consideration must be given to the placement of the precipitator to maximize its effectiveness. When your SMOG-HOG is used as a ducted source collector, the enclosure or pickup hood design is important for adequate capture of contaminants. Model SH-SSP-300 blowers have limited static pressure capacity. Check with factory for anticipated duct losses in excess of 0.5in (12.7 mm).! DANGER DO NOT OPERATE THIS EQUIPMENT IN THE PRESENCE OF COMBUSTIBLE VAPORS OR GASES 3.3 UNIT MOUNTING Carefully remove the unit from the shipping container, again inspecting for shipping damage. For ease of installation, open the access door and remove the unicell and filters from the cabinet. Supports: Units are designed for bottom support. Units may be mounted onto any flat surface such as a machine tool cabinet top or on an angle iron support base using the mounting feet on the unit. If units are to be hung from the ceiling, consult UAS for installation details. Prior to installation, verify you have at least 15" (381 mm) for door swing and component access on the door side of the unit. Allow 12" (305 mm) clearance from side obstructions to electrical box where the highvoltage power supply is located. Drain Connection: Units collecting oil should be tilted 1/2" NPT (6mm) toward drain on air entry end. Provisions should be made to assure a good drain connection. All units are manufactured with a sump knockout. Where oil collection is specified, sump is factory modified and supplied with a drain assembly or drain loop-trap assembly. 1
Units are supplied with terminal blocks for connection to 100-120V/1Ph/60Hz power. To avoid the risk of electrical shock and proper operation of the air cleaner when making the power connection make certain the air cleaner is grounded by connecting a good earth ground wire to the earth ground point in the electrical enclosure. Installation should conform to all national and local codes. 4. START-UP AND OPERATION For best results, the unit should be started before the air becomes contaminated, insuring clean air at all times. To start the unit, place the toggle switch in the on position. The unit has been thoroughly tested prior to shipment from the factory; however, there may be some initial arcing of the components at start-up. The arcing should cease after a few minutes of operation. An indicator light on the unit above the On-Off switch is illuminated during normal operation of the power pack and unicell. If the light fails to illuminate when the power is turned on, see Troubleshooting (section 6.4) for further instructions. Periodically, momentary shorts will occur indicated by the flickering indicator light. If the light is dim, fails to glow, or continues to flicker, the components may need cleaning or servicing (see Cleaning Instructions, Section 5.1). 5. MAINTENANCE! DANGER ELECTRICAL SHOCK HAZARD ELECTRICAL CONNECTIONS SHOULD ONLY BE MADE BY QUALIFIED PERSONNEL! CAUTION CLEANING AND SERVICING SHOULD ONLY BE DONE BY QUALIFIED AND TRAINED PERSONNEL Risk of electrical shock Disconnect from power source before servicing. Some collected contaminants may be hazardous. Consult factory or local safety personnel before servicing unit and for proper disposal of collected contaminants. 5.1 CLEANING INSTRUCTIONS 1. Discharge components (See figures 5 and 6): Turn unit off AND WAIT 30 SECONDS FOR HIGH VOLTAGE CHARGE TO BLEED DOWN. Open cabinet door. To discharge the cell, use an insulatedhandle screwdriver. First touch the blade across the unicell end plate and then across the high-voltage cell rod (insulated post). To discharge the ionizer, first touch the blade of an insulated handle screwdriver across the unicell end plate, and then across the ionizer wire support. Slide dirty collection components (pre-filter, unicell and after-filter) from cabinet. 2. To clean components: Soak in hot detergent solution for about 30 minutes. Shake components in the hot solution to remove loosened dirt. The detergent used must be inhibited for the protection of aluminum filters and cells. UAS offers an exclusive HOG- WASH detergent which can be purchased through UAS or your local representative. 3. To rinse components: Remove from detergent bath and immediately flush away any remaining residue. Rinse thoroughly with hot water. Shake off excess water. 4. To dry components: Place unicell and mesh filters in a warm room (with the plates standing vertically) until they have completely drained and are dry to the touch. Twenty minutes is normally satisfactory. 5. Wipe off contaminant from high-voltage insulators located on the cabinet wall. Do not use any abrasive cleaner or other material, which will harm the protective glaze on the insulators. 6. Component tracks and interior walls of the cabinets should be kept clean of contaminant buildup. Excess buildup can affect system performance. Wipe off periodically. 7. Periodically check for contaminant buildup in the blower compartment. Wipe down motor and blower housing as required and check for buildup on blower wheel. 8. Components must be reinstalled properly. Improperly installed components may result in loss of high-voltage and loss of efficiency. Good alignment is imperative for proper high-voltage feed. 9. After reinstalling components into the cabinet, close the cabinet door and turn on unit. Indicator light should illuminate. NOTE: If the unit snaps excessively, or if the indicator light fails to glow, remove components and allow more drying time. 2
5.2 REPLACING DAMAGED IONIZER WIRES 1. Remove the damaged wire from each spring. Also replace spring if it is damaged. 2. Loop one end of the new wire over the bottom spring, then extend the top spring and loop the end of the wire over the top spring. Pliers may aid in this procedure (Refer to Figure 4). NOTE: In the event that replacement wires are not immediately available, the ionizer may be left in service. Remove broken wire(s) and springs from the assembly. Operation with missing wires will result in reduced operating efficiency. 6. TROUBLESHOOTING! CAUTION TROUBLESHOOTING AND SERVICING PROCEDURES SHOULD BE PERFORMED BY 2. Unicell Ionizing Section The ionizing section supports thin tungsten wires which carry a positive charge of approximately 11 KVDC. This section electrically charges (ionizes) the contaminated particles being pulled through the unit. 3. Unicell Collection Section The collection section contains plates alternately charged to a positive voltage of approximately 6.1 KVDC. This section collects charged particles passing through the ionizer. 4. Media Paper Filter Models with optional media paper filter (HEPA or other types) located after the unicell provide additional filtering. 5. Air Mover The motor/blower pulls in the contaminated air and exhausts the clean air through the outlet. QUALIFIED PERSONNEL ONLY! CAUTION 6.1 TOOLS REQUIRED Screwdriver: 8 inches or longer with insulated plastic handle. Volt-Ohm meter: For checking 100-120 VAC input voltage, low-voltage DC and continuity (ohms). High-voltage probe: For checking high-voltage power supply (range: 0 to 15 KVDC) Amp probe (or clip-on amp meter): For checking motor current. 6.2 SYSTEM COMPONENTS 1. High Voltage Power Supply The power pack contains the necessary components to convert 100-130 volts, single phase, 60 Hertz (100-130/1/60) to the high-voltage DC required for the ionizer and collection cell. The power supply output circuit is limited to a maximum of 5.0mA to insure both equipment and personnel safety. In the event of a short circuit or other overload condition, the power supply is designed to cause the high voltage to collapse. When the voltage collapses, the indicator light will go out. When the overload is removed, the voltage will automatically build up to normal and the indicator light will illuminate. The power supply is self-protecting against overload. When the power is removed from the power supply circuit, an internal resistor bleeds off the residual charge on the collection cell. As a precaution, when the access door is opened, the blade of an insulated handle screwdriver should be used to ground components before removal (see grounding procedure, section 3.3). SOME COLLECTED CONTAMINANTS MAY BE HAZARDOUS. CONSULT UAS OR LOCAL SAFETY PERSONNEL BEFORE SERVICING UNIT, AND FOR PROPER DISPOSAL OF COLLECTED CONTAMINANTS 6.3 BEFORE TESTING Before testing of the electrical circuit, check unicell and cabinet for dirt buildup and clean if necessary. Check for broken ionizer wires, bent contact springs and other hardware necessary for electrical continuity. Check blower for dirt buildup. Inspect condition of drain. Verify unit is operating according to specifications. 3
6.4 TROUBLESHOOTING PROCEDURES Referencing the indicator light can generally isolate problems that cause loss of efficiency. When the light is on, high-voltage is present at the ionizer and collector terminals of the power pack. With light on and no highvoltage present at the ionizer or collector, an open circuit in the high-voltage path causes the difficulty. To measure the high-voltage, connect the high-voltage probe ground lead to the unicell frame (Refer to Figure 3). To measure the ionizer voltage, touch the probe to the ionizer wire connection through the hole in end of the unicell end plate. To measure the collector voltage, touch the probe to the end of the cell rod located in the center of one of the cell insulators. 1. If the indicator light is on and smoke is visible at the precipitator outlet, proceed as follows: A gradual decline in efficiency of smoke removal may be traced to the ionizer wire. A broken wire not shorted to ground can be responsible for non-ionized particles passing uncollected through the cell. Inspect for a coating on the ionizer wire that may be reducing the charging function. Wipe the wires and insulators with a detergent-soaked cloth to correct problem. With a total loss in efficiency, check for defective connection of high-voltage wires at the power pack or high-voltage insulators. Make certain there is a good ground connection from the unicell frame to the SH-SSP-300 cabinet. 2. If indicator light is out, proceed to isolate the difficulty as follows: Open access door, remove unicell and check for presence of nominal high voltage at cell and ionizer as previously described. If high voltage is present, the indicator light may be defective. Check for security of contact leads at lamp and power pack terminals. The lamp terminal marked (+) must be connected to the power supply terminal 9. Make sure power pack is grounded. With contacts and leads proven satisfactory, replace lamp. 3. If indicator light is out and no voltage is present at cell and ionzer, proceed as follows: Open the access door, remove unicell, and then close access door. Energize unit and observe indicator light. If the light comes on, the ionizer and cell component have shorted. Carefully check for presence of excessive dirt buildup or foreign material lodged between cell plates, bowed plates that would cause the cell to short out, or broken ionizer wires which are in contact with ground surfaces. Place cell and ionizer collection component back into the cabinet and close access door. If indicator light remains out, proceed as follows: Open electrical enclosure on cabinet and check for 100-130 VAC supply to power pack. If 100-130 VAC supply voltage is present, remove (red) high-voltage leads from the power pack terminals. Energize unit and observe indicator light. If light comes on, one of the high-voltage leads is shorted to ground. Check for defective (red) high-voltage leads and replace as necessary. 4. If indicator light is out with both (red) high voltage leads removed, and no high-voltage is present at output terminals: Replace the power supply. 7. REPLACEMENT PARTS Common replacement parts are shown on the following page. For additional information regarding your air cleaner, contact your local representative. For prompt service, please have available: 1. Unit model number (nameplate) 2. Unit serial number (nameplate) 3. Part number and part description Returning parts: When returning parts directly to UAS for any reason, call UAS at 1-800-231-4200 for a return authorization number before returning the parts. This number must be on the package being returned. 4
7.1 REPLACEMENT PARTS LIST Part No. Description Quantity 02-10561-G Indicator lamp, LED, 12V, 17mm Green 1 02-0524-S Unicell 6 wire SSP 300/600 1 03-0387 Ionizer wire set (6 looped 10mil 03-0387 wires) 1 36-0037 Spring, ionizer wire 12 37-0007 Insulator-cell, horseshoe 2 02-0747-SP Ionizer feed through insulator assembly 1 02-0748-SP Cell feed through insulator assembly 1 03-0313 Wire kit, high voltage 1 21-1216 Power supply, 120V, industrial-type 1 20-0326 Switch-toggle, SPST 1 20-0002 Plate switch ON/OFF 1 20-1239 Switch, PS enclosure interlock 1 20-0436 Switch, filter door interlock 1 37-0031 Insulating Material (for filter door interlock switch) 1 33-0032 Filter-mesh 10 x 15 3/4 2 36-0014 Spring, contact 2 36-0077 Spring, grounding 1 20-0288 Power cord 1 32-0071 Motor/Blower Assembly, 115V 1 For parts not listed above, consult UAS for assistance. 5
8. TROUBLESHOOTING TABLE PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTIONS 1. Control switch on, indicator lamp off, air mover operates. Defective lamp Faulty connection to lamp Replace lamp Check connection to lamp Loss of high voltage Check power supply 2. Control switch on, indicator lamp on, air mover does not operate. Air mover faulty Foreign object blocking air mover Replace air mover Clean foreign object from air mover Faulty control switch Replace control switch Connector not properly connected (at control switch) Check connection at control switch 3. Control switch on, air mover and lampl off Fault in 100-130 VAC supply line Safety interlock switch not engaged Correct wiring Engage safety interlock switch Safety interlock switch defective Replace safety interlock switch Control switch defective Replace control switch 4. Poor air quality Unicell dirty Clean unicell Unicell malfunction Check unicell for: Foreign matter between plates Ionizer wires loose or broken Defects in insulators Unicell installed backwards or upside down Install unicell correctly High-voltage contacts dirty Clean high-voltage contacts 5. High voltage output low or zero Loss of input 100-130 VAC Determine loss of input voltage Unicell malfunctioning Check unicell for: Foreign matter between plates Ionizer wires loose or broken Power supply defective Replace power supply 6
FIGURE 1 COLLECTION OF CONTAMINATED AIR FIGURE 2 CLEANING COMPONENTS 7
FIGURE 3 IONIZER AND CELL VOLTAGE MEASUREMENT FIGURE 4 IONIZER WIRE REPLACEMENT 8
FIGURE 5 DISCHARGING COLLECTION CELL FIGURE 6 DISCHARGING IONIZER 9
WIRING DIAGRAM 10
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UNITED AIR SPECIALISTS, INC. LIMITED WARRANTY UAS warrants to the original purchaser that all equipment will be free from defects in materials and workmanship for one year from the date of shipment from UAS (three years for Smokeeter and VisionAir models other than CC and DC series) and that major structural components on SFC and MCB series will be free from defects in materials and workmanship for ten years from the date of shipment from UAS. This warranty applies only if equipment is properly installed, maintained, and operated under normal conditions and does not apply to damage caused by corrosion, abrasion, abnormal use or misuse, misapplication, or normal wear and tear. This warranty will be void with respect to equipment that is subject to unauthorized repairs or modifications. UAS makes no warranty as to goods manufactured or supplied by others. This warranty is subject to any limitations in UAS quotation and may not be modified except by a written instrument signed by the President or Vice President of Sales of UAS. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER WRITTEN, ORAL OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR NONINFRINGEMENT. As Purchaser's exclusive remedy for any defects in the equipment, UAS will exchange or repair any defective parts during the warranty period, provided such parts are returned, prepaid, to UAS' factory. The obligation of UAS is limited to furnishing replacement parts F.O.B. UAS' factory or making repairs at UAS' factory of any parts that are determined, upon inspection by UAS, to be defective. In no event will UAS be responsible for labor or transportation charges for the removal, reshipment or reinstallation of the parts. IN NO EVENT WILL UAS BE RESPONSIBLE FOR ANY SPECIAL OR CONSEQUENTIAL DAMAGES. 4440 Creek Road Cincinnati, Ohio 45242 USA National Phone: 1-800-252-4647 Telephone: (513) 891-0400 Fax: (513) 891-4882 http://www.uasinc.com AN ISO9001 CERTIFIED COMPANY 2003, 2005 United Air Specialists Part No. 44-10282-0001 09/05 United Air Specialists, Inc. reserves the right to change design or specifications without notice.