Clean Air America WeldStation Basic User Manual

Learn how to properly setup and maintain your Clean Air America WeldStation Basic to get the most out of your unit.

Document #CAA-00036.R001

T ABLE OF C ONTENTS

TABLE OF CONTENTS .......................................................................................................................................... 2

SHIPPING RECEIVING, AND INSPECTION ............................................................................................................. 5

R ECEIVING AND I NSPECTION ............................................................................................................................................. 5 B EFORE I NSTALLATION B EGINS .......................................................................................................................................... 6

WELD STATION DESCRIPTION ............................................................................................................................. 7

FEATURES AND SPECIFICATIONS ......................................................................................................................... 8

G ENERAL F EATURES ........................................................................................................................................................ 8 B LOWER / M OTOR S PECIFICATIONS ................................................................................................................................... 9 U NIT W EIGHT ................................................................................................................................................................ 9

INSTALLATION .................................................................................................................................................. 10

G ENERAL I NSTALLATION G UIDELINES ................................................................................................................................ 10 T OOLS N EEDED FOR I NSTALLATION ................................................................................................................................... 11 Required Tools: .................................................................................................................................................... 11 Optional / Recommended Tools: ......................................................................................................................... 12 S INGLE U NIT P ARTS L IST ................................................................................................................................................ 14 D UAL U NIT P ARTS L IST .................................................................................................................................................. 16 W ARNINGS AND L ABELS ................................................................................................................................................. 18 M OVING THE W ELD S TATION M AIN U NIT ......................................................................................................................... 19 B RINGING THE M AIN U NIT U PRIGHT , N O L IFTING T OOL ....................................................................................................... 21 B RINGING THE M AIN U NIT U PRIGHT , W ITH L IFTING T OOL ................................................................................................... 23 M OVING THE S ECONDARY B OOTHS .................................................................................................................................. 25 I NSTALLING THE F LAT G ASKET ON THE U NIT ....................................................................................................................... 26 I NSTALLING THE F LAT G ASKET ON THE COVER P LATES .......................................................................................................... 27

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I NSTALLING THE C OVER P LATES ....................................................................................................................................... 28 A TTACHING THE S ECONDARY B OOTH ................................................................................................................................ 29 R EMOVING THE I NTERNAL P ANEL B AFFLES ......................................................................................................................... 31 I NSTALLING THE I NTERNAL P ANEL B AFFLES ........................................................................................................................ 32 I NSTALLING THE I NTAKE S PARK B AFFLES ............................................................................................................................ 33 R EMOVING THE T ABLE S LIDES ......................................................................................................................................... 35 I NSTALLING THE T ABLE S LIDES AND T ABLES ........................................................................................................................ 36 I NSTALLING THE L EVER H ANDLES ..................................................................................................................................... 38 I NSTALLING THE [O PTIONAL ] D UST T RAYS ......................................................................................................................... 39 I NSTALLING THE H OLE P LUGS .......................................................................................................................................... 41

AIR AND ELECTRICAL CONNECTION DIAGRAMS ................................................................................................. 42

COMPRESSED AIR CONNECTION ........................................................................................................................ 44

A IR R EGULATOR ........................................................................................................................................................... 44 A IR F ILTER ................................................................................................................................................................... 44 D RY A IR ...................................................................................................................................................................... 45 S HUT O FF V ALVE .......................................................................................................................................................... 45

ELECTRICAL CONNECTIONS ................................................................................................................................ 46

C ONNECTING THE S ECONDARY B OOTH L IGHT ( S ) ................................................................................................................. 48 P OWER D ISCONNECT S WITCH / E MERGENCY S HUT O FF S WITCH ............................................................................................ 50 P OWER S TART / S TOP S WITCH ........................................................................................................................................ 51 L IGHT S WITCH .............................................................................................................................................................. 52 B REAKERS ................................................................................................................................................................... 52 K EY L ATCH .................................................................................................................................................................. 53

SYSTEM CONTROLLER ....................................................................................................................................... 54

F ILTER C LEANING C ONTROLS ........................................................................................................................................... 55 A UTO M ODE : .............................................................................................................................................................. 56 M ANUAL M ODE : T IMED ................................................................................................................................................ 56 M ANUAL M ODE : C OUNT ............................................................................................................................................... 57 M ANUAL M ODE : V TEST ................................................................................................................................................. 57 O PTION M ODE : S HUT D OWN P LS # .................................................................................................................................. 57

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O PTION M ODE : S HUTDWN DEL P ..................................................................................................................................... 57 O PTION M ODE : R UN P LS DEL P ....................................................................................................................................... 58 O PTION M ODE : A LARM DEL P ......................................................................................................................................... 58 O PTION D EFAULTS ........................................................................................................................................................ 58

BLOWER ROTATION .......................................................................................................................................... 59

STARTUP PROCEDURES ..................................................................................................................................... 60

SHUTDOWN PROCEDURES ................................................................................................................................ 60

MAINTENANCE ................................................................................................................................................. 61

C ATCH B ASIN M AINTENANCE .......................................................................................................................................... 61 D UST T RAY M AINTENANCE ............................................................................................................................................. 63 C LEANING THE I NTAKE S PARK B AFFLES .............................................................................................................................. 65 R EMOVING THE I NTAKE S PARK B AFFLES ............................................................................................................................ 66 C LEANING THE I NTAKE A REA ........................................................................................................................................... 67 C ARTRIDGE F ILTER M AINTENANCE ................................................................................................................................... 68 Filter Features ...................................................................................................................................................... 68 Filter Maintenance ............................................................................................................................................... 68 Where to Start ..................................................................................................................................................... 69 How to Determine the Filter Change Interval ...................................................................................................... 69 What determines the maximum acceptable pressure differential reading? ....................................................... 71 How to replace filters ........................................................................................................................................... 72

APPENDIX A: FILTER MAINTENANCE LOG SHEET ................................................................................................ 76

APPENDIX B: DIMENSIONAL DRAWINGS ............................................................................................................ 77

APPENDIX C: EXPLODED VIEWS ......................................................................................................................... 96

APPENDIX D: WIRING DIAGRAMS (MARCH 2011+) .......................................................................................... 107

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S HIPPING R ECEIVING , AND I NSPECTION

R ECEIVING AND I NSPECTION

Congratulations on the purchase of your new Clean Air America Weld Station System!

Upon receipt of the Weld Station, remove the master packing list from the unit and reconcile it with the total shipment.

Report any discrepancies to Clean Air America as soon as possible.

Remove the packaging from the unit; then remove the unit from the pallet.

Carefully inspect the unit and any other items shipped with the unit for any damage that may have been incurred during shipping. If damage is found, report it to the shipping company and Clean Air America immediately. Weld tables, spark baffles, and dust trays (if purchased) are packaged and shipped inside the booth area of the main unit or secondary booth.

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The Reverse Flow TM and Metal Mesh spark Baffles require being shipped separately. Accessories may be packaged and shipped on a separate pallet depending on the order. In some cases these parts may be packaged inside the booth area of the main unit or secondary booth. A bolt package is included for each unit and booth combination. This bolt package includes lever handles for the filter doors only of the main unit and flat gasket for the entire Weld Station assembly. It is taped to the table slides inside the unit or booth.

B EFORE I NSTALLATION B EGINS

Prior to using your Weld Station, it must be fully assembled and placed in its final operating location.

Adequate electrical and compressed air must also be connected to the Weld Station. These connections are defined in “Electrical Connections” and "Compressed Air Connections" sections of this manual.

During installation, always be careful. The Weld Station is a top heavy unit and may require experienced personal to move and set up.

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W ELD S TATION D ESCRIPTION

DISCLAMER: The Clean Air America Weld Station is designed to accumulate smoke residue / particles and other by-products of the manufacturing process. The nature of these accumulations may be flammable. Operating the Weld Station with these materials could result in a fire inside the unit. The Weld Station is not recommended for use with highly combustible materials or explosive materials or particles.

The Clean Air America Weld Station consists of:

Weld Station Housing

Motor / Blower System

Four Cartridge Filters

Online Automatic Pulse Filter Cleaning System

The “dirty air” inlet is located inside the booth at the back of the booth portion. Metal Mesh spark baffles and Reverse Flow TM spark baffles protect the inlet. The “clean air” outlet is located on the top of the unit above the motor access panel. The optional silencers or exhaust deflectors may be installed on the outlet end. A large opening door provides easy access to the internal cartridge filter, and bolt on

access panels allow access to the motor compartment and valve compartment for maintenance.

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F EATURES AND S PECIFICATIONS

G ENERAL F EATURES

Patented Down-Flow Air Cleaning Technology

Filter Element Design: 12.75" OD x 26" Long, Flame Retardant, 100% Cellulose

(4) Filters for a total area of 904 sq. ft.

Silencing: Built-in Acoustical Lining

Heavy Steel Construction and Powder-Coat Paint Finish

Pulse Air Reservoir; (2) 1" Valves; 1" Compressed Air Connection

1.0 ft 3 Valve Pulse at 70 - 90 psi

Clean Air AutoPulse TM Controller: A Programmable Pulse Controller with Filter Differential Readout; Manual Mode Options

Motor Contactor and Overload; On / Off Push Button with Center Light; Disconnect Switch

(2) 24" x 24" x 2" Metal Mesh spark baffles and (2) 24" x 24" x 2" Reverse Flow TM spark baffles for each unit and each booth

Customizable Filters

73 dB Noise level on OSHA scale

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B LOWER / M OTOR S PECIFICATIONS

Backward Incline, Air Foil High Efficiency Plug type Blower(s)

Single Phase 115, 208, or 230 Volts

3 Phase 208, 230, or 460 Volts

3450RPM

3600-RPM NEMA MG-1; 230-460 V/60/3 (std.)

U NIT W EIGHT

The weight of the Weld Station unit can vary depending on the configuration, application, and accessories purchased. This is due to the wide selection of motors, blowers, filters, and accessories Clean Air America has to offer. Please see the following chart for approximate weights.

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I NSTALLATION

The Weld Station requires some minor assembly.

A standard unit will come with an exhaust cover pre-installed.

The unit and a booth are integrated into a single machine referred to as the 'main unit'.

A secondary booth can be attached to the main unit and creating a "Dual Weld Station". If no secondary booth is used, then the main unit is referred to as a "Single Weld Station".

See the 'Weld Station Accessories User Manual' for accessory assembly instructions.

G ENERAL I NSTALLATION G UIDELINES

Clean Air America’s Weld Station units are shipped via freight and generally arrive on a flat bed trailer. The main units are partially crated, on a pallet, and are shipped laying on their sides. The secondary booths are partially crates and shipped upright. Use a fork lift truck, driven by a qualified individual, to remove the crate / pallet from the truck. Occasionally, fork extensions are helpful.

Once the Weld Station unit is inside the facility, ready to be uncrated, please proceed cautiously. Banding straps and plastic wrap must be removed.

Weld Station units are heavy and tend to be top heavy. The motor and the majority of the metal is located at the top of the unit. Please see the "Unit Weight" section for proper weights.

There are (4) steel plate eyelets vertical at the top of unit. These are the lifting lugs.

There are (9) floor mounting holes on the bottom flange of the unit

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T OOLS N EEDED FOR I NSTALLATION

The Following tool lists are given as a general outline. Additional tools may be used or substituted based on availability. The required tool list is given as a bare minimum required to assembling a Weld Station. Powered tools are recommended.

Required Tools:

(1) 5 /

(2) 7 /

32 " Allen Wrench

16 " Box Head Wrenches

(1) Fork Lift Truck

(1) Utility Knife

(1) Set of Lifting Chains

(1) Set of Ratchet Straps

(1) Small Flat Head Screwdriver [for Electrical Connections]

(2) 9 /

16 " Box Head Wrenches

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Optional / Recommended Tools:

(1) Cordless Drill

(1) Ratchet

(1) Air Ratchet

(1) 7 /

5 /

7 / 16 " Drive Socket

16 " Socket Bit

(1)

32 " Allen Bit

(1)

(1) 9 /

9 / 16 " Drive Socket

16 " Socket Bit

(1) Flashlight

(1)

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(1) Set of Fork Extensions

(1) Fork Lifting Tool

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S INGLE U NIT P ARTS L IST

The following parts are shipped with each Weld Station Single (no secondary booth). Colors of some parts may very if a custom color was ordered. Please confirm that all parts have been shipped before beginning assembly.

(30) 1/4" - 20 x 1.0" black socket head cap screw

(30) 1/4" Black Flat Washers

(30) 1/4" Black Lock Washers

(1) Flat Gasket, 25' each [May arrive in 50' rolls]

(42) 1/4" Black Nuts

(3) Locking Hole Plugs

(2) Black Lever Handles

(1) Electrical Box Key

(2) 3/8" Lock Nuts

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(2) Internal Panel Baffles [pre- installed]

(2) Table Slides [pre-installed]

(1) Welding Table

(2) Reverse Flow TM Spark Baffles

(2) Metal Mesh Spark Baffles

(3) 19" x 27" Plenum Cover Plates

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D UAL U NIT P ARTS L IST

The following parts are shipped with each Weld Station Dual (one secondary booth attached to main unit). Colors of some parts may very if a custom color was ordered. Please confirm that all parts have been shipped before beginning assembly.

(50) 1/4" - 20 x 1.0" black socket head cap screw

(50) 1/4" Black Flat Washers

(50) 1/4" Black Lock Washers

(50) 1/4" Black Nuts

(4) Locking Hole Plugs

(1) 25' Roll of Flat Gasket

(2) Black Lever Handles

(1) Electrical Box Key

(2) 3/8" Lock Nuts

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(2) Internal Panel Spark Baffles if the secondary booth is 5' or 6' wide, (3) Internal Panel Spark Baffles if the secondary booth is 3' or 4' wide [pre- installed]

(4) Table Slides [pre-installed]

(2) Welding Table

(2) Reverse Flow TM Spark Baffles if the secondary booth is 5' or 6' wide, (3) Reverse Flow TM Spark Baffles if the secondary booth is 3' or 4' wide

(4) Metal Mesh Spark Baffles if the secondary booth is 5' or 6' wide, (3) Metal Mesh Spark Baffles if the secondary booth is 3' or 4' wide

(4) 19" x 27" Plenum Cover Plates

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W ARNINGS AND L ABELS

HIGH VOLTAGE: The voltage of the Weld Station is dangerous once connected to a power supply. Incorrect installation may cause damage to the equipment, serious injury, or death. Consequently, it is essential to comply with instructions in this manual, local and national safety rules, and follow all safety procedures including proper lock out and tag out procedures.

GROUND CONNECTION: Proper grounding of the equipment and electrical panel is essential. Do not attempt to operate the equipment without electrically grounding the panel. The connection to the earth ground must be proper and provide a low impedance path to the earth to prevent hazardous voltages from appearing on equipment

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M OVING THE W ELD S TATION M AIN U NIT

There are various ways to move the Weld Station main unit.

If the Weld Station unit has NOT been uncrated or is still on the pallet, then it can easily be moved by using a fork lift truck. Place the forks under the pallet's main beams and simply lift the unit. Keep in mind, the motor end (top) of the unit is heavier and forks may need to be shifted toward the motor end. If the Weld Station unit has been uncrated, then it can easily be moved by using a fork lift truck. Attach the lifting chains or cables to the fork head ache bar. Attach the other end of the lifting chains or cables to the lifting lugs. The top of the unit can then be lifted using the fork lift truck. Place a wooden '2 x 4 underneath the raised end of the unit. This wood piece will create a gap allowing the forks to be slid under the unit. make sure not to scratch or damage the unit. If the Weld Station unit is uncrated and upright, then the unit can still be moved with a fork lift truck. Place the forks under the unit portion of the main Weld Station unit. Card board or rubber padding can be placed on the forks to prevent scratching of the unit. Make sure the forks are on both side of the light(s) / cables to prevent damaging the lights. Do NOT place the

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forks under the lights. Do NOT let the forks enter the intake at the back of the booth area. The Weld Station unit is top heavy and must be prevented from falling backwards during movement. It is recommend that the top of the unit is bound to the mast of the fork lift truck during movement. This can be done by wrapping a strap around the unit and mast. Another method is to attach a chain or cable between the mast and the lifting lugs.

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B RINGING THE M AIN U NIT U PRIGHT , N O L IFTING T OOL

NOTE:

Please be sure the chain hoist, come along, or chain/cable, is rated for that amount of weight to be lifted.

Properly sized chain or cable can be attached to header bar on a fork lift truck. The chain or cable can then be connected to the lifting lugs of the unit. The forklift truck can then be used to lift and move the unit. Other methods include attaching a chain hoist or come along, or both to the eyelets provided at the top of the unit. When the unit is being lifted, the bottom of the unit may shift. If possible, brace the bottom of the unit to prevent slipping. A '2 x 4' brace is fastened to the front floor flanges of the booth. This is used during shipment to prevent the collapse of the booth side walls. This '2 x 4' should be kept in place while bringing the unit upright to prevent damage.

SLOWLY hoist the unit up, supporting it whenever and wherever possible.

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DO NOT let the unit slam suddenly when bringing the unit into the upright position. This can cause damage to the unit. If risers are being used, then attach the risers before bringing the unit upright. See the Weld Station Accessories user manual for additional instructions.

Please proceed cautiously.

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B RINGING THE M AIN U NIT U PRIGHT , W ITH L IFTING T OOL

NOTE:

Please be sure the chain hoist, come along, or chain/cable, is rated for that amount of weight to be lifted.

Properly sized chain or cable can be attached to a lifting tool on a fork lift truck. The chain or cable can then be connected to the lifting lugs of the unit. The forklift truck can then be used to lift and raise the unit. Other methods include attaching a chain hoist or come along, or both to the eyelets provided at the top of the unit. When the unit is being lifted, the bottom of the unit may shift. If possible, brace the bottom of the unit to prevent slipping. A '2 x 4' brace is fastened to the front floor flanges of the booth. This used during shipment to prevent the collapse of the booth side walls. This '2 x 4' should be kept in place while bringing the unit upright to prevent damage.

SLOWLY hoist the unit up, supporting it whenever and wherever possible.

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Please proceed cautiously.

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M OVING THE S ECONDARY B OOTHS

If the secondary or slave booth has NOT been uncrated, then it can easily be moved by using a fork lift truck. Place the forks under the pallet's main beams and simply lift the unit. Make sure to lift the booths from the side of the pallet. If the secondary or slave booth has been uncrated, then the booth can still be moved with a fork lift truck. Place the forks under the bottom of the intake panel of the booth. Card board or rubber padding can be placed on the forks to prevent scratching of the unit. Do NOT place the forks under the lights. Do NOT let the forks enter the intake at the back of the booth.

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I NSTALLING THE F LAT G ASKET ON THE U NIT

Flat Gasket must be places around the outside of the plenum opening before assembly. This should only be done around the opening being mated to the secondary booth.

The flat gasket must be cut to length from the roll. For each opening, the following pieces should be cut (2) 19" long, and (2) 25" Long. The 19" long pieces are placed above and below the opening. These will cover all (3) bolt holes above the opening and all (3) bolt holes below the opening. The 25" long pieces are placed on the sides of the opening. These gasket pieces will be between the upper and lower gasket pieces and will cover the (2) bolt holes on each side of the opening.

The (4) gasket pieces must be placed centered over the bolt pattern.

Once all four flat gasket pieces are placed, there should be no gap between the gaskets.

Once all four flat gasket pieces are placed, then punch a hole into the gasket at each bolt hole to allow a bolt to pass through. Be careful not to damage the gasket.

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I NSTALLING THE F LAT G ASKET ON THE COVER P LATES

Flat Gasket must be places around the outside of all the cover plates before assembly onto the unit.

The flat gasket must be cut to length from the roll. For each opening, the following pieces should be cut (2) 19" long, and (2) 25" Long. The 19" long pieces are placed along the top and bottom short sides of the cover plate. These will cover all (3) bolt holes above the opening and all (3) bolt holes below the opening. The 25" long pieces are placed on the long sides of the cover plate. These gasket pieces will be between the upper and lower gasket pieces and will cover the (2) bolt holes on each side of the opening.

The (4) gasket pieces must be placed centered over the bolt pattern.

Once all four flat gasket pieces are placed, there should be no gap between the gaskets.

Once all four flat gasket pieces are placed, then punch a hole into the gasket at each bolt hole to allow a bolt to pass through. Be careful not to damage the gasket.

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I NSTALLING THE C OVER P LATES

Any intake plenum opening not used for connecting the main unit to the secondary booth must be covered using one of the plenum cover plates.

It may be necessary to install the cover plates before setting the units in the final location. Obstructions such as walls or other Weld Stations my prevent or hinder access.

Flat Gasket must be installed on the main unit and booths before the cover plates can be installed.

Align the cover plate blocking the intake plenum opening so that the bolt holes are aligned.

Fasten the cover plate to the main unit or booth using (10) 1/4" - 20 x 1.0" black socket head cap screw, (20) black 1/4" flat washers, (10) black 1/4" lock washers, and (10) black 1/4"-20 nuts. The screw heads should be on the outside of the unit.

For most installations, it will be necessary to remove the internal baffle plates to install the cover plates.

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A TTACHING THE S ECONDARY B OOTH

The Weld Station main unit can have a secondary welding booth attached for added welding stations. This booth can be attached to either side or onto the back of the booth. This achieved by connection through the rectangular opening with bolt patterns on the sides and back of the unit intake plenum. The secondary booth will have a matching openings with bolt patterns in the intake plenum.

NOTE:

Before connecting the main unit and secondary booth, the Flat Gasket must be installed around the connection opening.

Remove the table slides from the adjoining booth walls. The same bolt is used for mounting both table slides to the common booth walls.

For easy access to the bolt holes, remove the internal spark baffles.

Do not install of the metal mesh spark baffles and Reverse Flow TM spark baffles until after the unit and booth have been joined together.

If the spark baffles are already

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installed, remove them. See the 'Removing the Spark Baffles' section of the user manual. Place the main unit in the final location. This may require bolting on some of the cover plates before placement due to obstructions. If risers are being used, they must be installed on the unit before final placement. Place the secondary booth next to the main unit. This may require bolting on some of the cover plates before placement due to obstructions. If risers are being used, they must be installed on the booth before final placement. Slide the secondary booth into place and align the plenum openings and bolt hole patterns. Each rectangular opening has a ten hole bolt pattern. Fasten the secondary booth to the main unit using (10) 1/4" - 20 x 1.0" black socket head cap screw, (20) black 1/4" flat washers, (10) black 1/4" lock washers, and (10) black 1/4"-20 nuts.

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R EMOVING THE I NTERNAL P ANEL B AFFLES

The internal spark baffles must be removed for some Weld Station installations. Internal baffles are located in both the main unit and secondary booth. 1. Begin by loosening and removing the bolts on both the left and the right side of the baffle plate. This should allow the baffle plate to fall free from the vertical supports. 2. Reach into the intake opening and slide the baffle midway to the opposite side of the booth in front of the vertical supports. 3. Rotate the baffle so that one side begins to twist into the back of the back of plenum area. 4. Tilt the baffle plate at a 45 degree angle to remove it through the front intake of the booth.

5. Repeat steps 1 through 4 with any other baffles.

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I NSTALLING THE I NTERNAL P ANEL B AFFLES

The internal spark baffles must be installed before using the Weld Station. Internal baffles are located in both the main unit and secondary booth.

1. Begin by tilting the baffle at about a 45 degree angle

2. Slide the baffle into the intake plenum through the intake opening. Slide it in past the internal baffle support. 3. Once the baffle is entirely inside the plenum area, rotate the baffle so that it is vertical.

4. Then slide the baffle forward in front on the intake supports.

5. Once the baffle is vertical in front of the supports, place it flush on the supports and slide it up so that the bolt pattern on the baffle is aligned with the bolt pattern on the baffle supports. 6. Fasten the baffle to the supports inside the plenum area using (6) 1/4" - 20 x 0.75" zinc plated hex head bolts, (6) 1/4" zinc plated flat washers, and (6) 1/4" zinc plated lock washers.

7. Repeat steps 1 through 6 with any other baffles.

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I NSTALLING THE I NTAKE S PARK B AFFLES

All of the intake spark baffles must be installed before using the Weld Station. These baffles are the first defense in stopping sparks from passing into the weld station. Smaller width secondary booths will only have one spark baffle of each type. The metal mesh spark baffles must be installed behind the Reverse Flow TM spark baffles. 1. First, carefully slide the top of the metal mesh spark baffle upward into the top channel of the intake at a slight angle (approximately 10 degrees). 2. Then push the bottom of the metal mesh spark baffle inward so that the baffle is vertical and aligned with the bottom channel of the intake. 3. Next slide the metal mesh spark baffle down into the bottom channel of the intake. 4. Slide the metal mesh filter all the way to the right hand side of the intake. Make sure it is seated in the bottom of the channel and shifted so that it is flush with the side of the intake. 5. Repeat steps 1 through 4 for the other metal mesh spark baffle; however slide the second baffle all the way to the left.

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6. Repeat steps 1 through 4 for the (2) Reverse Flow TM spark baffles; placing first on the right and the second on the left.

NOTE:

Make sure when installing the intake baffles that they are installed in the correct direction. On both the metal mesh and Reverse Flow TM spark baffles, there are markings to show the proper air flow direction. The arrows must point into the intake. Additionally, the Reverse Flow TM spark baffles must be installed so that the baffles are horizontal.

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R EMOVING THE T ABLE S LIDES

Before the unit and secondary booth can be attached together, the table slides of the adjoining walls must be removed. The same bolt is used to hold the table slides of Loosen and remove the (4) bolts holding the table slide onto the side wall of the booth or unit. Retain these bolts.

Hold onto the table slide to support it while loosening the bolts and prevent damage due to falling.

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I NSTALLING THE T ABLE S LIDES AND T ABLES

Once the unit and secondary booth are attached together, the table slides and welding tables can be installed into both the secondary booth and the main unit. Place the table slide on the wall of the unit so that the slide channels are horizontal and the channels open to the inside of the booth.

Align the bolt hole pattern on the table slide to the bolt hole pattern on the side wall of the booth.

Fasten the table slide to the wall of the booth using (4) 1/4" - 20 x 1.0" black socket head cap screws, (8) black 1/4" flat washers, (4) black 1/4" lock washers, and (4) black 1/4"-20 nuts. The screw heads should be on the outside of the booth. When a secondary booth is being attached on the side of a main unit, (2) table slides are being attached to a common booth wall. In this situation, each of the (4) bolts must be used to attach both table slides. If the table slide is being installed on the common wall between a main unit and secondary booth, the bolt head can be on either side. Once all the table slides have been attached to the booth walls, insert the table into the channel at the desired height. The table simply slides into the channels of the table slides on both sides of the booth. Make sure the table is being inserted into the same height on

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both sides of the booth so that the tables is not tilted.

Once the table has been installed, it can be moved by simply pulling the table out and sliding it into another height channel. The table can also be left partially extended from the booth to allow welding of larger objects outside the booth. When doing so, make sure the welding does not exceed range of the airflow for the booth.

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I NSTALLING THE L EVER H ANDLES

For each main unit, there are two lever handles. These handles must be installed in the filter compartment door for increased ease of maintenance. Remove the bolts holding the filter door shut. The door was bolted shut during shipping to prevent damage to the lever handles. Make sure to keep the 3/8" flat washers; however, the 3/8" retaining bolts can be discarded.

The filter door may swing open allowing access to the filter compartment.

Swing the filter door closed.

Place a 3/8" zinc flat washer on each of the lever handles.

Place the threaded stud of the lever handles through the holes in the filter door arms.

Screw the lock nut onto the back of the lever handle. This will keep the lever handle attached to the door during maintenance and prevent the loss of hardware.

Screw the lever handle into the weld nut and tighten the door down.

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I NSTALLING THE [O PTIONAL ] D UST T RAYS

NOTE:

Dust trays are an optional add on and are not necessary for most operations.

If purchased, there are two dust trays for each main unit. These dust trays must be placed in the filter compartment. As the self cleaning cycle is activated, dust will be blown from the filters and accumulate in the dust tray. See the 'Maintenance' section for proper servicing of the dust trays. Remove the lever handles holding the filter door shut. Make sure to keep the 3/8" flat washers. See the "Installing the Lever Handles" section if necessary.

Swing the filter door open to allow access to the filter compartment.

Slide the first dust tray under the front two filter rings which support the front two filters.

Slide the first dust tray all the way to the left of the filter compartment.

Slide the first dust tray down to the floor of the catch area. It should be sitting below the corner of the slanted panel so that dust is directed into the dust tray.

Slide the second dust tray under the front

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filter rings which support the front two filters.

Slide the second dust tray all the way to the right of the filter compartment.

Slide the first dust tray down to the floor of the catch area beside the first dust tray.

Swing the filter door closed.

Place a 3/8" zinc flat washer on each of the lever handles.

Place the threaded stud of the lever handles through the holes in the filter door arms.

Screw the lever handle into the weld nut and tighten the door down.

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I NSTALLING THE H OLE P LUGS

Once the unit is fully assembled and operational, place all of wire track hole plugs into the sides and back of the unit. There is a 'T' shaped wire track built into the bottom of the plenum. Each end of the 'T' had an exposed 1-1/2" circular opening.

Each side of the main unit and secondary booth has a circular opening.

The back of the main unit and secondary booth each have a circular opening.

Simply press the open side of the plug into the circular opening. It will lock in place.

It may be necessary to install the hole plugs before setting the units in the final location. Obstructions such as walls or other Weld Stations my prevent or hinder access.

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A IR AND E LECTRICAL C ONNECTION D IAGRAMS

Weld Station User Manual, March 2011

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Weld Station User Manual, March 2011

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C OMPRESSED A IR C ONNECTION

In order for the automatic pulse filter cleaning system to operate, the Clean Air America Weld Station requires a compressed air connection to be made.

The compressed air inlet is located on the top of the Weld Station in front of the exhaust panel.

This Weld Station compressed air inlet supply is a 1” NPT male fitting.

Use a regulator to adjust the pressure to 70 to 90 PSI.

A dryer may be needed to condition the air before entering the Weld Station.

1.0 ft 3 Valve Pulse at 70 - 90 psi

5/8" Minimum compressed air supply line required; 1" Recommended

NOTE:

Do not operate the Weld Station for an extended period of time without an appropriate compressed air supply. Doing so will greatly diminish the life of the filter cartridges.

A IR R EGULATOR

The compressed air for the Weldstation must be regulated at 70 to 90 PSI. A Regulator is used to allow the high-pressure air supply lines or tanks to be reduced to safe and usable pressure for pulsing the unit. If the pressure is too low, the valves may not properly clean the filters. If the pressure is too high, it may damage the valves.

A IR F ILTER

The compressed air for the Weldstation must be clean. Dirty air entering the system can cause damage to pneumatic components. The air should be filtered to remove all contaminants by the compressed air supply system prior to entering the Weldstation.

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D RY A IR

The air supply to the weld station must be dry or drained. Water carried with air into the Weldstation can wash away lubricating oil. This can mean excessive wear to pneumatic components and higher maintenance expenses. Without adequate lubrication pneumatic components can run sluggishly and inefficiently be prone to air leakage. Water in the supply line must be removed using a dryer or water drain trap.

S HUT O FF V ALVE

Each unit must be fitted with a shut off valve capable of being locked out with blow off capability. Safety procedures such as lock out / tag out procedures must be followed with pneumatic as well as electrical systems. This means, the valve must be a 2-way valve which will exhaust the air from the Weldstation when the shut off valve has been locked out. The exhaust port should be fitted with a pneumatic muffler to reduce noise if above unacceptable levels.

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E LECTRICAL CONNECTIONS

Clean Air America Weld Stations can be set up to operate on various power sources. Please see the following electrical chart based on the specified power. To ensure proper operation, a certified Clean Air America, Inc. installer or professional electrician should perform power connections. Any damage incurred from improper electrical power connection will void the warranty of the Weld Station. The incoming power is connected to the unit at the conduit connection located on the top of the unit in front of the exhaust panel. For convenience and quick connection, there is a 3/4" Weather tight female EMT fitting. The EMT fitting can be remove leave a female Rigid Metal Conduit (RMC) connection.

When power is brought into the Weld Station through the EMT Conduit fitting, it will enter the electrical box at the top of the box.

First make the ground connection into the grounding terminal block.

The incoming power wires must be terminated on the incoming side of the power disconnect switch / emergency shut off switch (L1, L2, L3).

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